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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE SYSTEM MX–1
MANUAL TRANSAXLE SYSTEM
PROBLEM SYMPTOMS TABLEUse the table below to help find the cause of the problem.The numbers indicate the likelihood of the possible causes indescending order. Check each part in order. Replace parts asnecessary.
Symptom Suspected area See page
Noise
1. Oil (Level low) MX-2
2. Oil (Wrong) MX-2
3. Gear (Input shaft) (Worn or damaged) MX-78
4. Gear (Output shaft) (Worn or damaged) MX-89
5. Bearing (Input shaft) (Worn or damaged) MX-76
6. Bearing (Output shaft) (Worn or damaged) MX-86
7. Bearing (Differential case) (Worn or damaged) MX-101
Oil leakage
1. Oil (Level too high) MX-2
2. Gasket (Damaged) MX-41
3. Oil seal (Worn or damaged) MX-4
Hard or impossible to shift
1. Control cable (Faulty) MX-16
2. Shift fork (Worn) MX-56
3. Synchronizer ring ((Input shaft) Worn or damaged) MX-78
4. Synchronizer ring (Output shaft) (Worn or damaged) MX-89
5. Shift key spring (Input shaft) (damaged) MX-76
6. Shift key spring (Output shaft) (damaged) MX-86
7. Gear (Input shaft) (damaged) MX-78
8. Gear (Output shaft) (damaged) MX-89
9. Hub sleeve (Input shaft) (damaged) MX-78
10. Hub sleeve (Output shaft) (damaged) MX-89
Jumps out of gear
1. Shift fork (Worn) MX-56
2. Gear (Input shaft) (Worn or damaged) MX-78
3. Gear (Output shaft) (Worn or damaged) MX-89
4. Bearing (Input shaft) (Worn or damaged) MX-76
5. Bearing (Output shaft) (Worn or damaged) MX-86
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MX–2 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE OIL
MX
MANUAL TRANSAXLE OIL
ON-VEHICLE INSPECTION1. INSPECT TRANSAXLE OIL
(a) Stop the vehicle in a level place.(b) Remove the transmission filler plug and the gasket.(c) Check that the oil surface is within 5 mm (0.20 in.) of
the bottom of the transmission filler plug opening.NOTICE:• Excessively large or small amounts of oil may
cause problems.• After replacing the oil, drive the vehicle and
check the oil level again.(d) Check for oil leakage when the oil level is low.(e) Install the transmission filler plug and a new gasket.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
0 to 5 mm(0 to 0.20 in.)
D025304E01
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C50 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEALMX–3
TRANSMISSIONC50MANUAL TRANSAXLE
DIFFERENTIAL OIL SEAL
COMPONENTS
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
8.5 (87, 75 in.*lbf)
74 (755, 55)
29 (300, 22)
FRONT DRIVE SHAFT HOLE
SNAP RING LH
FRONT DRIVE SHAFT HOLESNAP RING RH
COTTER PIN
CLIP216 (2,203, 160)
49 (500, 36)
FRONT AXLE HUB LH NUT
FRONT DRIVE SHAFT ASSEMBLY LH
FRONT DRIVE SHAFT ASSEMBLY RH
FRONT STABILIZER
LINK ASSEMBLY LH
FRONT SUSPENSION ARM
SUB-ASSEMBLY LOWER NO.1 LH
SPEED SENSORFRONT LH
98 (999, 72)
w/ABS:
TIE ROD END SUB-ASSEMBLY LH
C115301E13
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MX–4C50 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL
MX
TRANSMISSION CASE OIL SEAL
TRANSAXLE CASE OIL SEAL
Apply MP grease
Non-reusable part
C108463E01
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C50 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL MX–5
REMOVAL1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. DRAIN TRANSAXLE OIL(a) Remove the filler plug and the gasket.(b) Remove the drain plug and gasket, and then drain
the manual transaxle oil.(c) Install a new gasket and the drain plug.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
3. REMOVE FRONT WHEELS
4. REMOVE FRONT AXLE HUB LH NUT (See page DS-3)
5. REMOVE FRONT AXLE HUB RH NUTHINT:The removal procedure for the RH side is the same asthat for the LH side.
6. SEPARATE SPEED SENSOR FRONT LH (w/ ABS)(See page DS-3)
7. SEPARATE SPEED SENSOR FRONT RH (w/ ABS)HINT:The separation procedure for the RH side is the same asthat for the LH side.
8. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH (See page DS-4)
9. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RHHINT:
The separation procedure for the RH side is the same asthat for the LH side.
10. SEPARATE TIE ROD END SUB-ASSEMBLY LH (Seepage DS-3)
11. SEPARATE TIE ROD END SUB-ASSEMBLY RHHINT:The separation procedure for the RH side is the same asthat for the LH side.
12. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH(See page DS-4)
13. SEPARATE FRONT STABILIZER LINK ASSEMBLYRHHINT:The separation procedure for the RH side is the same asthat for the LH side.
14. SEPARATE FRONT AXLE ASSEMBLY LH (See pageDS-4)
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MX–6 C50 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL
MX
15. SEPARATE FRONT AXLE ASSEMBLY RHHINT:The separation procedure for the RH side is the same asthat for the LH side.
16. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (Seepage DS-5)
17. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (Seepage DS-5)
18. REMOVE TRANSAXLE CASE OIL SEAL(a) Using SST, remove the oil seal.
SST 09308-00010
19. REMOVE TRANSMISSION CASE OIL SEAL(a) Using SST, remove the oil seal.
SST 09308-00010
INSTALLATION1. INSTALL TRANSMISSION CASE OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.(b) Using SST and a hammer, install the new oil seal.
SST 09309-37010Drive in depth:
9.6 to 10.2 mm (0.378 to 0.402 in.)NOTICE:Do not damage the oil seal lip.
2. INSTALL TRANSAXLE CASE OIL SEAL
(a) Coat the lip of a new oil seal with MP grease.(b) Using SST and a hammer, install the new oil seal.
SST 09710-26011 (09710-05061)Drive in depth:
1.6 to 2.2 mm (0.063 to 0.087 in.)NOTICE:Do not damage the oil seal lip.
3. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (Seepage DS-13)
4. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (Seepage DS-14)
SST
C094266E01
SST
D025305E01
SST
9.6 to 10.2 mm
(0.378 to 0.402 in.)C070067E01
SST
1.6 to 2.2 mm
(0.063 to 0.087 in.)
C070068E01
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C50 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL MX–7
5. INSTALL FRONT AXLE ASSEMBLY LH (See page DS-14)
6. INSTALL FRONT AXLE ASSEMBLY RHHINT:The installation procedure for the RH side is the same asthat for the LH side.
7. INSTALL FRONT STABILIZER LINK ASSEMBLY LH(See page DS-14)
8. INSTALL FRONT STABILIZER LINK ASSEMBLY RHHINT:The installation procedure for the RH side is the same asthat for the LH side.
9. INSTALL TIE ROD END SUB-ASSEMBLY LH (Seepage DS-15)
10. INSTALL TIE ROD END SUB-ASSEMBLY RHHINT:The installation procedure for the RH side is the same as
that for the LH side.
11. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH (See page DS-14)
12. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RHHINT:The installation procedure for the RH side is the same asthat for the LH side.
13. INSTALL SPEED SENSOR FRONT LH (w/ ABS) (Seepage DS-15)
14. INSTALL SPEED SENSOR FRONT RH (w/ ABS)HINT:The installation procedure for the RH side is the same asthat for the LH side.
15. INSTALL FRONT AXLE HUB LH NUT (See page DS-15)
16. INSTALL FRONT AXLE HUB RH NUTHINT:The installation procedure for the RH side is the same asthat for the LH side.
17. INSTALL FRONT WHEELS18. CONNECT CABLE TO NEGATIVE BATTERY
TERMINALTorque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
19. ADD TRANSAXLE OIL
20. INSPECT AND ADJUST TRANSAXLE OIL (See pageMX-2)
21. INSPECT ABS SPEED SENSOR SIGNAL(See page BC-14)
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MX–8 C50 MANUAL TRANSAXLE – DIFFERENTIAL OIL SEAL
MX
22. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page SP-2)
23. CHECK FOR TRANSAXLE OIL LEAKAGE
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MX–8C50 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY
MX
TRANSMISSIONC50 MANUALTRANSAXLE
FLOOR SHIFT LEVER ASSEMBLY
COMPONENTS
CONSOLE BOX ASSEMBLY REAR
FLOOR SHIFT SHIFT LEVER ASSEMBLY
SHIFT LEVER KNOB SUB-ASSEMBLY
TRANSMISSION CONTROL
CABLE ASSEMBLY12 (122, 8.9)
x4
CONSOLE BOX REAR COVER
CONSOLE BOX
CARPET
CLIPCLIP
N*m (kgf*cm, ft*lbf) :Specified torque
for Hatchback:
C106956E05
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C50 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLYMX–9
for Sedan:
CONSOLE BOX CARPET
CONSOLE UPPER REAR
PANEL SUB-ASSEMBLY
INSTRUMENT PANEL FINISH PANEL LOWER CENTER
REAR CONSOLE BOX ASSEMBLY
SHIFT LEVER KNOB SUB-ASSEMBLY
UPPER CONSOLE PANEL SUB-ASSEMBLY
C136395E01
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MX–10 C50 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY
MX
REMOVAL1. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for
Hatchback) (See page IP-68)
2. REMOVE CONSOLE BOX ASSEMBLY REAR (forHatchback) (See page IP-69)
3. REMOVE INSTRUMENT PANEL FINISH PANEL
LOWER CENTER (for Sedan) (See page ME-138)
4. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (forSedan) (See page IP-84)
5. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY(for Sedan) (See page IP-84)
6. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Sedan) (See page IP-84)
7. REMOVE CONSOLE BOX CARPET (for Sedan) (Seepage IP-85)
8. REMOVE REAR CONSOLE BOX ASSEMBLY (forSedan) (See page IP-85)
9. DISCONNECT TRANSMISSION CONTROL CABLEASSEMBLY(a) Remove the clip and disconnect the control select
cable from the shift lever.(b) Turn the lock to release it and separate the control
select cable from the shift lever retainer.(c) Disconnect the control shift cable from the shift
lever.(d) Turn the lock to release it and separate the control
shift cable from the shift lever retainer.
10. REMOVE FLOOR SHIFT SHIFT LEVER ASSEMBLY(a) Remove the 4 bolts and remove the shift lever.
INSTALLATION1. INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY(a) Install the shift lever with the 4 bolts.
Torque: 12 N*m (122 kgf*cm, 8.9 ft.*lbf)
C106358
C106358
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C50 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY MX–11
2. CONNECT TRANSMISSION CONTROL CABLEASSEMBLY(a) Install the control shift cable onto the shift lever
retainer.NOTICE:• Install the cable with the protruding portion of
the cable outer facing upward.• After installing, check that the lock of the
cable outer is protruding beyond portion A,as shown in the illustration.
(b) Connect the control shift cable to the shift lever.
(c) Install the control select cable onto the shift leverretainer.NOTICE:• Install the cable with the protruding portion of
the cable outer facing upward.• After installing, check that the lock of the
cable outer is protruding beyond portion A,as shown in the illustration.
(d) Connect the control select cable to the shift lever.NOTICE:• Connect the control select cable so that the
adjusting mechanism lock of the controlselect cable is installed on the left side of thevehicle.
• Insert the clip in the direction shown in theillustration.
(e) Adjust the length of the control select cable.(1) Slide the adjuster case cover in the direction
shown in the illustration (Illustration A).(2) Gently pull the cable rod toward the rear of the
vehicle by hand to pull the cable taut.(3) Press the lock piece into the adjuster case and
lock it (Illustration B).(4) Slide the cover in the direction shown in the
illustration (Illustration C).NOTICE:Slide the cover past the protrusion of thelock piece (Illustration D).
3. INSTALL CONSOLE BOX ASSEMBLY REAR (forHatchback) (See page IP-79)
4. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (forHatchback) (See page IP-80)
5. INSTALL REAR CONSOLE BOX ASSEMBLY (forSedan) (See page IP-88)
Protruding Portion Lock A
C106359E01
Protruding Portion Lock A
C106360E01
C106361E01
Lock PieceCover
Adjuster Case
A
B
C
D
C108468E02
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MX–12 C50 MANUAL TRANSAXLE – FLOOR SHIFT LEVER ASSEMBLY
MX
6. INSTALL CONSOLE BOX CARPET (for Sedan) (Seepage IP-88)
7. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Sedan) (See page IP-89)
8. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY(for Sedan) (See page IP-89)
9. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (forSedan) (See page IP-89)
10. INSTALL INSTRUMENT PANEL FINISH PANELLOWER CENTER (for Sedan) (See page ME-142)
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MX–14C50 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE
MX
for Sedan:
CONSOLE BOX CARPET
CONSOLE UPPER REAR
PANEL SUB-ASSEMBLY
INSTRUMENT PANEL FINISH PANEL LOWER CENTER
REAR CONSOLE BOX ASSEMBLY
SHIFT LEVER KNOB SUB-ASSEMBLY
UPPER CONSOLE PANEL SUB-ASSEMBLY
C136395E01
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C50 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLEMX–15
EXHAUST PIPE
ASSEMBLY FRONT
FRONT FLOOR HEATINSULATOR NO.1
GASKET
COMPRESSION SPRING
COMPRESSION SPRING
GASKET
x2
x2
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
5.5 (56, 49 in.*lbf)
43 (438, 32)
5.5 (56, 49 in.*lbf)
43 (438, 32)
x2
C121106E01
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MX–16 C50 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE
MX
REMOVAL1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (forHatchback) (See page IP-68)
3. REMOVE CONSOLE BOX ASSEMBLY REAR (for
Hatchback) (See page IP-69)
4. REMOVE INSTRUMENT PANEL FINISH PANELLOWER CENTER (for Sedan) (See page ME-138)
5. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (forSedan) (See page IP-84)
6. REMOVE UPPER CONSOLE PANEL SUB-ASSEMBLY(for Sedan) (See page IP-84)
7. REMOVE CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Sedan) (See page IP-84)
8. REMOVE CONSOLE BOX CARPET (for Sedan) (Seepage IP-85)
9. REMOVE REAR CONSOLE BOX ASSEMBLY (forSedan) (See page IP-85)
10. DISCONNECT OXYGEN SENSOR CONNECTOR
11. REMOVE EXHAUST PIPE ASSEMBLY FRONT (Seepage EX-5)
12. REMOVE FRONT FLOOR HEAT INSULATOR NO.1(a) Remove the 2 bolts and nut and remove floor heat
insulator No.1.
13. REMOVE TRANSMISSION CONTROL CABLEASSEMBLY(a) Disconnect the control shift cable from the shift
lever.(b) Turn the lock to release it and separate the control
shift cable from the shift lever retainer.(c) Remove the clip and disconnect the control select
cable from the shift lever.(d) Turn the lock to release it and separate the control
select cable from the shift lever retainer.
(e) Remove the 2 clips and the 2 washers, and
disconnect the 2 cables from the transaxle.(f) Remove the 2 clips and disconnect the 2 cablesfrom the control cable bracket.
C115305
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C50 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE MX–17
(g) Remove the 3 nuts and remove the transmissioncontrol cable.
INSTALLATION1. INSTALL TRANSMISSION CONTROL CABLE
ASSEMBLY(a) Install the control cable with the 3 nuts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Install the control shift cable onto the shift leverretainer.NOTICE:• Install the cable with the protruding portion of
the cable outer facing upward.• After installing, check that the lock of the
cable outer is protruding beyond portion A,as shown in the illustration.
(c) Connect the control shift cable to the shift lever.(d) Install the control shift cable onto the control cable
bracket with a new clip.(e) Connect the control shift cable to the transaxle
through the washer.
(f) Install the control select cable onto the shift leverretainer.NOTICE:• Install the cable with the protruding portion of
the cable outer facing upward.• After installing, check that the lock of the
cable outer is protruding beyond portion A,as shown in the illustration.
C106362
C106362
Protruding Portion Lock A
C106359E01
Protruding Portion Lock A
C106360E01
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MX–18 C50 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE
MX
(g) Connect the control select cable to the shift leverwith the clip.NOTICE:• Connect the control select cable so that the
adjusting mechanism lock of the controlselect cable is installed on the left side of thevehicle.
• Insert the clip in the direction shown in theillustration.
(h) Install the control select cable onto the control cablebracket with a new clip.
(i) Connect the control select cable to the transaxlethrough the washer.
(j) Adjust the length of the control select cable.(1) Slide the adjuster case cover in the direction
shown in the illustration (Illustration A).(2) Gently pull the cable rod toward the rear of the
vehicle by hand to pull the cable taut.(3) Press the lock piece into the adjuster case and
lock it (Illustration B).(4) Slide the cover in the direction shown in the
illustration (Illustration C).NOTICE:Slide the cover past the protrusion portionof the lock piece (Illustration D).
2. INSTALL FRONT FLOOR HEAT INSULATOR NO.1(a) Install floor heat insulator No. 1 with the 2 bolts and
nut.Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
3. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See
page EX-8)
4. CONNECT OXYGEN SENSOR CONNECTOR
5. INSTALL CONSOLE BOX ASSEMBLY REAR (forHatchback) (See page IP-79)
6. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (forHatchback) (See page IP-80)
7. INSTALL REAR CONSOLE BOX ASSEMBLY (forSedan) (See page IP-88)
8. INSTALL CONSOLE BOX CARPET (for Sedan) (See
page IP-88)9. INSTALL CONSOLE UPPER REAR PANEL SUB-
ASSEMBLY (for Sedan) (See page IP-89)
10. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY(for Sedan) (See page IP-89)
11. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (forSedan) (See page IP-89)
12. INSTALL INSTRUMENT PANEL FINISH PANELLOWER CENTER (for Sedan) (See page ME-142)
C106361E01
Lock PieceCover
Adjuster Case
A
B
C
D
C108468E02
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C50 MANUAL TRANSAXLE – TRANSMISSION CONTROL CABLE MX–19
13. CONNECT CABLE TO NEGATIVE BATTERYTERMINALTorque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
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MX–20C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
TRANSMISSIONC50 MANUALTRANSAXLE
MANUAL TRANSAXLE ASSEMBLY
COMPONENTS
HOOD SUB-ASSEMBLY
COWL TO REGISTER DUCT
SUB-ASSEMBLY NO.2
COWL TOP VENTILATOR
LOUVER LH
COWL TOP VENTILATOR
LOUVER SUB-ASSEMBLY
FRONT WIPER ARM AND
BLADE ASSEMBLY LH
FRONT WIPER ARM AND
BLADE ASSEMBLY RH
HOOD TO COWL
TOP SEAL
WINDSHIELD WIPERMOTOR AND LINK
N*m (kgf*cm, ft*lbf) :Specified torque
6.5 (66, 58 in.*lbf)
13 (133, 9.6)
7.0 (71, 62 in.*lbf)
26 (265, 19)
HEAD CAP
CLIP
HEAD CAP
13 (133, 9.6)
26 (265, 19)
x9
x2
x3
COWL TOP PANEL OUTER
for Hatchback:
C116836E06
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLYMX–21
COWL SIDE VENTILATOR
SUB-ASSEMBLY LH
COWL SIDE VENTILATOR
SUB-ASSEMBLY RH
COWL TOP PANEL OUTER
COWL TOP VENTILATOR
LOUVER SUB-ASSEMBLY
FRONT WIPER ARM AND BLADE ASSEMBLY RH
HOOD TO COWL TOP SEAL
N*m (kgf*cm, ft*lbf) :Specified torque
5.5 (56, 49 in.*lbf)
13 (133, 9.6)
26 (265, 19)
CLIP
HEAD CAP
FRONT WIPER ARM AND
BLADE ASSEMBLY LH
HEAD CAP
HOOD SUB-ASSEMBLY
WINDSHIELD WIPER MOTOR AND LINK
x3
x2
x8
26 (265, 19)
13 (133, 9.6)
for Sedan:
COWL TOP TO COWL INNER BRACE
6.5 (66, 58 in.*lbf)
6.5 (66, 58 in.*lbf)FRONT AIR
SHUTTER SEAL
C135789E02
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MX–22C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
N*m (kgf*cm, ft*lbf) :Specified torque
7.8 (80, 69 in.*lbf)
19 (194, 14)
17 (175, 13)
3.5 (36, 31 in.*lbf)
7.0 (71, 62 in.*lbf)
BATTERY CLAMP BOLT
x2
x2
x5
7.0 (71, 62 in.*lbf)
AIR CLEANER
ASSEMBLY
AIR CLEANER BRACKET
BATTERY
BATTERY CARRIER
BATTERY CLAMP
SUB-ASSEMBLY
BATTERY TRAY
CYLINDER HEAD COVER NO.2
C121105E02
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLYMX–23
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
8.5 (87, 75 in.*lbf)
74 (755, 55)
29 (300, 22)
FRONT DRIVE SHAFT HOLESNAP RING LH
FRONT DRIVE SHAFT HOLE
SNAP RING RH
COTTER PIN
CLIP216 (2,203, 160)
49 (500, 36)
FRONT AXLE HUB LH NUT
FRONT DRIVE SHAFT ASSEMBLY LH
FRONT DRIVE SHAFT ASSEMBLY RH
FRONT STABILIZER
LINK ASSEMBLY LH
FRONT SUSPENSION ARM
SUB-ASSEMBLY LOWER NO.1 LH
SPEED SENSOR
FRONT LH
98 (999, 72)
w/ABS:
TIE ROD END SUB-ASSEMBLY LH
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MX–24C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
ENGINE UNDER COVER LH
COLUMN HOLE COVER
SILENCER SHEET
ENGINE UNDERCOVER RH
FRONT SUSPENSION
CROSSMEMBER
SUB-ASSEMBLY
STEERING SLIDING
YOKE SUB-ASSEMBLY
TRANSVERSE ENGINE
ENGINE MOUNTING
CONTROL BRACKET
N*m (kgf*cm, ft*lbf) :Specified torque
120 (1,224, 89)
5.0 (51, 44 in.*lbf)
39 (398, 29)
70 (714, 52)
95 (969, 70)
160 (1,631, 118)
x2
x2
x4
x3
x2x2
x2x4
5.0 (51, 44 in.*lbf)
CLIP
28 (290, 21)
x2
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLYMX–25
STARTER ASSEMBLY
CLUTCH RELEASECYLINDER ASSEMBLY
CONTROL CABLE BRACKET
MANUAL TRANSAXLE ASSEMBLY
TRANSMISSION CONTROL CABLE ASSEMBLY
TRANSVERSE ENGINE
ENGINE MOUNTING BRACKET
TRANSVERSE ENGINE
ENGINE MOUNTING
INSULATOR
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
64 (653, 47)
25 (255, 18)
52 (530, 38)
33 (336, 24)
37 (377, 27)
12 (120, 8.7)
CLIP
CLIP
CLIP
WASHER
WASHER
CLIP
x2
x4
x5
x2
x5
37 (377, 27)
33 (336, 24)52 (530, 38)
12 (122, 8.9)
12 (122, 8.9)
FLYWHEEL HOUSING
SIDE COVER
13 (129, 9.4)
x2
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MX–26 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
REMOVAL1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE COLUMN HOLE COVER SILENCER SHEET(See page PS-74)
3. REMOVE STEERING SLIDING YOKE SUB-
ASSEMBLY (See page PS-74)
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE ENGINE UNDER COVER RH
7. DRAIN TRANSAXLE OIL(a) Remove the filler plug and the gasket.(b) Remove the drain plug and the gasket, and then
drain the manual transaxle oil.(c) Install a new gasket and the drain plug.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
8. REMOVE HOOD SUB-ASSEMBLY
9. REMOVE FRONT WIPER ARM AND BLADEASSEMBLY LH (See page WW-17)
10. REMOVE FRONT WIPER ARM AND BLADEASSEMBLY RH (See page WW-17)
11. REMOVE HOOD TO COWL TOP SEAL (See pageWW-18)
12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback) (See page WW-18)
13. REMOVE COWL TOP VENTILATOR LOUVER LH (forHatchback) (See page WW-18)
14. REMOVE WINDSHIELD WIPER MOTOR AND LINK(for Hatchback) (See page WW-19)
15. REMOVE COWL TO REGISTER DUCT SUB-ASSEMBLY NO.2 (for Hatchback) (See page EM-122)
16. REMOVE COWL TOP PANEL OUTER (for Hatchback)(See page EM-123)
17. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLYLH (for Sedan) (See page WW-10)
18. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLYRH (for Sedan) (See page WW-10)
19. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan) (See page WW-10)
20. REMOVE WINDSHIELD WIPER MOTOR AND LINK(for Sedan) (See page WW-10)
21. REMOVE FRONT AIR SHUTTER SEAL (for Sedan)(See page EM-123)
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MX–28 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
32. REMOVE CONTROL CABLE BRACKET(a) Remove the 2 bolts and the control cable bracket.
33. DISCONNECT WIRE HARNESS(a) Remove the bolt, then disconnect the wire harness.
34. DISCONNECT CONNECTOR(a) Disconnect the back-up light switch connector.
35. REMOVE STARTER ASSEMBLY (See page ST-9)
36. REMOVE FRONT AXLE HUB LH NUT (See page DS-3)
37. REMOVE FRONT AXLE HUB RH NUTHINT:The removal procedure for the RH side is the same asthat for the LH side.
38. SEPARATE SPEED SENSOR FRONT LH (w/ ABS)(See page DS-3)
39. SEPARATE SPEED SENSOR FRONT RH (w/ ABS)HINT:The separation procedure for the RH side is the same asthat for the LH side.
40. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH (See page DS-4)
41. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RHHINT:The separation procedure for the RH side is the same asthat for the LH side.
42. SEPARATE TIE ROD END SUB-ASSEMBLY LH (Seepage DS-3)
43. SEPARATE TIE ROD END SUB-ASSEMBLY RH
HINT:The separation procedure for the RH side is the same asthat for the LH side.
44. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH(See page DS-4)
45. SEPARATE FRONT STABILIZER LINK ASSEMBLYRHHINT:The separation procedure for the RH side is the same asthat for the LH side.
C106374
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–29
46. SEPARATE FRONT AXLE ASSEMBLY LH (See pageDS-4)
47. SEPARATE FRONT AXLE ASSEMBLY RHHINT:The separation procedure for the RH side is the same asthat for the LH side.
48. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (Seepage DS-5)
49. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (Seepage DS-5)
50. SUSPEND ENGINE ASSEMBLY(a) Install the 2 hangers in the correct direction.(b) Attach the engine chain hoist to the hangers.
CAUTION:Do not attempt to hang the engine by hookingthe chain to any other part.Parts No.:
Engine Hanger: 12281-21010Bolt:
91642-81025Torque: 40 N*m (408 kgf*cm, 29 ft.*lbf)
51. REMOVE FRONT SUSPENSION CROSSMEMBERSUB-ASSEMBLY (See page PS-76)
52. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING CONTROL BRACKET(a) Remove the 4 bolts and the engine mounting control
bracket.
53. SUPPORT MANUAL TRANSAXLE ASSEMBLY
54. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR(a) Remove the bolt and nut, then separate the engine
mounting insulator LH.(b) Remove the 5 bolts and the engine mounting
insulator LH.
Front Rear
D030284E01
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MX–30 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
55. REMOVE TRANSVERSE ENGINE ENGINEMOUNTING BRACKET(a) Remove the 4 bolts and the engine mounting
bracket LH.
56. REMOVE MANUAL TRANSAXLE ASSEMBLY(a) Remove the 7 bolts and the manual transaxle.
INSTALLATION1. INSTALL MANUAL TRANSAXLE ASSEMBLY
(a) Align the input shaft with the clutch disc and installthe manual transaxle onto the engine.
(b) Install the 7 bolts.Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
2. INSTALL TRANSVERSE ENGINE ENGINEMOUNTING BRACKET(a) Install the engine mounting bracket LH with the 4
bolts.Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
3. INSTALL TRANSVERSE ENGINE ENGINEMOUNTING INSULATOR(a) Install the engine mounting insulator LH with the 5
bolts.Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
(b) Install the engine mounting bracket LH and engineinsulator LH with the bolt and nut.Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
C121108
C063143
C063143
C121108
C106372
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–31
4. INSTALL TRANSVERSE ENGINE ENGINEMOUNTING CONTROL BRACKET(a) Install the engine mounting control bracket with the
4 bolts.Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf)
5. INSTALL FRONT SUSPENSION CROSSMEMBERSUB-ASSEMBLY (See page PS-77)
6. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (Seepage DS-13)
7. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (Seepage DS-14)
8. INSTALL FRONT AXLE ASSEMBLY LH
9. INSTALL FRONT AXLE ASSEMBLY RH (See pageDS-14)
10. INSTALL FRONT STABILIZER LINK ASSEMBLY LH(See page DS-14)
11. INSTALL FRONT STABILIZER LINK ASSEMBLY RHHINT:The installation procedure for the RH side is the same asthat for the LH side.
12. INSTALL TIE ROD END SUB-ASSEMBLY LH (Seepage DS-15)
13. INSTALL TIE ROD END SUB-ASSEMBLY RHHINT:The installation procedure for the RH side is the same asthat for the LH side.
14. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH (See page DS-14)
15. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RHHINT:The installation procedure for the RH side is the same asthat for the LH side.
16. INSTALL SPEED SENSOR FRONT LH (w/ ABS) (Seepage DS-15)
17. INSTALL SPEED SENSOR FRONT RH (w/ ABS)HINT:
The installation procedure for the RH side is the same asthat for the LH side.
18. INSTALL FRONT AXLE HUB LH NUT (See page DS-15)
19. INSTALL FRONT AXLE HUB RH NUTHINT:The installation procedure for the RH side is the same asthat for the LH side.
20. INSTALL STARTER ASSEMBLY (See page ST-17)
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MX–32 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
21. CONNECT CONNECTOR(a) Connect the back-up light switch connector.
22. CONNECT WIRE HARNESS(a) Connect the wire harness with the bolt.
Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf)
23. INSTALL CONTROL CABLE BRACKET(a) Install the control cable bracket with the 2 bolts.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
24. CONNECT TRANSMISSION CONTROL CABLEASSEMBLY(a) Connect the 2 cable ends and install the 2 washers
and the 2 clips.(b) Install 2 new clips onto the control cable bracket.
25. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY(a) Install the clutch release cylinder and clutch pipe
with the 4 bolts.Torque: 12 N*m (120 kgf*cm, 8.7 ft.*lbf) for bolt
A12 N*m (122 kgf*cm, 8.9 ft.*lbf) for boltB
C108079
C106374
C115305
A
AB B
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY MX–33
26. INSTALL BATTERY CARRIER(a) Install the battery carrier with the 5 bolts.
Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
27. INSTALL BATTERY TRAY
28. INSTALL BATTERY
29. INSTALL BATTERY CLAMP SUB-ASSEMBLY
30. INSTALL AIR CLEANER BRACKET(a) Install the air cleaner bracket with the 2 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
31. INSTALL AIR CLEANER ASSEMBLY (See page EM-146)
32. INSTALL CYLINDER HEAD COVER NO.2 (See pageIG-10)
33. INSTALL COWL TOP PANEL OUTER (for Hatchback)(See page EM-146)
34. INSTALL COWL TO REGISTER DUCT SUB-ASSEMBLY NO.2 (for Hatchback) (See page EM-147)
35. INSTALL WINDSHIELD WIPER MOTOR AND LINK(for Hatchback) (See page WW-21)
36. INSTALL COWL TOP VENTILATOR LOUVER LH (forHatchback) (See page WW-21)
37. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback) (See page WW-21)
38. INSTALL COWL TOP PANEL OUTER (for Sedan) (Seepage EM-147)
39. INSTALL FRONT AIR SHUTTER SEAL (for Sedan)(See page EM-148)
40. INSTALL WINDSHIELD WIPER MOTOR AND LINK(for Sedan) (See page WW-12)
41. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan) (See page WW-12)
42. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY
RH (for Sedan) (See page WW-13)43. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY
LH (for Sedan) (See page WW-13)
44. INSTALL HOOD TO COWL TOP SEAL (See page WW-22)
45. INSTALL FRONT WIPER ARM AND BLADEASSEMBLY LH (See page WW-22)
46. INSTALL FRONT WIPER ARM AND BLADEASSEMBLY RH (See page WW-23)
47. INSTALL HOOD SUB-ASSEMBLY
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MX–34 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE ASSEMBLY
MX
48. INSPECT HOOD SUB-ASSEMBLY (See page ED-3)
49. ADJUST HOOD SUB-ASSEMBLY (See page ED-4)
50. ADD TRANSAXLE OIL
51. INSPECT AND ADJUST TRANSAXLE OIL (See pageMX-2)
52. INSTALL ENGINE UNDER COVER RH
53. INSTALL ENGINE UNDER COVER LH
54. INSTALL FRONT WHEELS
55. INSTALL STEERING SLIDE YOKE SUB-ASSEMBLY(See page PS-79)
56. INSTALL COLUMN HOLE COVER SILENCER SHEET(See page PS-79)
57. CONNECT CABLE TO NEGATIVE BATTERYTERMINALTorque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
58. INSPECT ABS SPEED SENSOR SIGNAL (w/ ABS)(See page BC-14)
59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page SP-2)
60. CHECK FOR EXHAUST GAS LEAKAGE
61. CHECK FOR TRANSAXLE OIL LEAKAGE
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–35
TRANSMISSIONC50MANUAL TRANSAXLE
MANUAL TRANSAXLE UNIT
COMPONENTS
BEARING LOCK PLATE
FRONT TRANSAXLE CASE OIL SEAL
MANUAL TRANSAXLE
CASE RECEIVER
OUTPUT SHAFT
FRONT BEARING
SPEEDOMETER DRIVEN HOLE
COVER SUB-ASSEMBLY
TRANSAXLE CASE
OIL SEAL
TRANSMISSION MAGNET
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
11 (115, 8.3)
INPUT SHAFT FRONT BEARING
FRONT DIFFERENTIAL CASE
FRONT PLATE WASHER
FRONT DIFFERENTIAL CASE FRONT
TAPERED ROLLER BEARING
11 (115, 8.3)
29 (300, 22)
11 (115, 8.3)
O-RINGx3
11 (115, 8.3)
O-RING
CLIP
SPEED SENSOR
DRIVEN GEAR
w/o ABS:
TRANSAXLE CASE
Apply MP grease Apply gear oil
SPEEDOMETER
SENSOR
OUTPUT SHAFT COVER
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MX–36 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
25 (250, 18)
WASHER
DUST BOOT
LOCK PIN
Apply MP grease
GASKET
20 (200, 14)
DUST BOOT
WASHER
LOCK PIN
12 (120, 8.7)
x4
x2
12 (120, 8.7)
CONTROL BELL
CRANK DUST COVER
12 (120, 8.7)
CONTROL SHAFT COVER
CONTROL SHAFT COVER OIL SEAL
FLOOR SHIFT CONTROL SHIFT LEVER
SELECTING BELL
CRANK ASSEMBLY
SHIFT AND SELECT LEVER
SHAFT ASSEMBLY
SHIFT AND SELECT LEVER SHAFT OIL SEAL
SHIFT LEVER DAMPER
SHIFT AND SELECT LEVER SHAFTSLIDE BALL BEARING
Precoated part
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–37
BACK-UP LIGHT SWITCH ASSEMBLY
LOCK BALL ASSEMBLY NO.1
LOCK BALL ASSEMBLY NO.2
MANUAL TRANSMISSION CASE
MANUAL TRANSMISSION CASE
COVER SUB-ASSEMBLY
MANUAL TRANSMISSION FILLER PLUG
REVERSE RESTRICT
PIN ASSEMBLY
SHIFT GATE PIN
TRANSMISSION
CASE OIL SEAL
39 (400, 29)
Precoated part
40 (410, 30)
11 (112, 8.1)
29 (300, 22)
13 (130, 9.3)
29 (300, 22)
39 (400, 29)
17 (175, 13)
18 (185, 14)
29 (300, 22)
17 (175, 13)
GASKET
GASKET
SLOTTED
SPRING PIN
Apply MP grease
FR DIFFERENTIAL CASE
REAR TAPERED
ROLLER BEARING
FR DIFFERENTIAL CASE
REAR PLATE WASHER
WASHER
x9
x13
GASKET
DRAIN PLUG
SUB-ASSEMBLY
OIL RECEIVER
PIPE NO. 1
OIL RECEIVER PIPE NO. 2
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable partC120728E01
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MX–38 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
OUTPUT SHAFT REAR
BEARING HOLE SNAP RING
5TH DRIVEN GEAR
5TH GEAR
5TH GEAR NEEDLE ROLLER BEARING
INPUT SHAFT REAR
BEARING HOLE SNAP RING
SYNCHRONIZER RING NO.3
TRANSMISSION CLUTCH HUB NO.3
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
27 (280, 20)
Precoated part
5TH GEAR BEARING SPACER
SYNCHROMESH SHIFTING KEY SPRING
SNAP RINGSYNCHROMESH SHIFTING KEY SPRING
SYNCHROMESH SHIFTING KEY x3
x5
BEARING RETAINER REAR
118 (1,200, 87)
TRANSMISSION HUB
SLEEVE NO. 3
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–39
GEAR SHIFT FORK
SHAFT NO.3
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part Precoated part
GEAR SHIFT FORK NO.3
GEAR SHIFT FORK
SHAFT NO.1
GEAR SHIFT FORK SHAFT NO.2
REVERSE SHIFT ARM
BRACKET ASSEMBLY
17 (175, 13)
Apply MP grease Apply gear oil
GEAR SHIFT FORK NO.2
GEAR SHIFT HEAD NO.1
SNAP RING
BALL
COMPRESSION SPRINGSPRING SEAT
SPRING SEAT
COMPRESSION SPRING
SNAP RING
GEAR SHIFT FORK NO.1
BALL
22 (224, 16)
SPRING SEAT
COMPRESSION SPRING
16 (160, 12)
SNAP RING SNAP RING
BALL
REVERSE SHIFT FORK
BALL
16 (160, 12)
16 (160, 12)
16 (160, 12)
22 (224, 16)
22 (224, 16)
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MX–40 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
INPUT SHAFT ASSEMBLY
DIFFERENTIAL
CASE ASSEMBLY
FR DIFFERENTIAL CASEFRONT TAPERED
ROLLER BEARING
FR DIFFERENTIAL CASE
REAR TAPERED
ROLLER BEARING
REVERSE IDLER GEAR SHAFT BOLT
REVERSE IDLER
GEAR SUB-ASSEMBLY
N*m (kgf*cm, ft*lbf) :Specified torque
Non-reusable part
29 (300, 22)
OUTPUT SHAFT ASSEMBLY
REVERSE IDLER THRUST WASHER
GASKET
Apply gear oil
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–41
DISASSEMBLY1. REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the manual transmission filler plug andgasket from the manual transmission case.
2. REMOVE DRAIN PLUG SUB-ASSEMBLY(a) Remove the drain plug sub-assembly and gasket
from the manual transmission case.
3. REMOVE SPEEDOMETER DRIVEN HOLE COVERSUB-ASSEMBLY(a) Remove the bolt and speedometer driven hole
cover sub-assembly from the transaxle case.(b) Remove the O-ring from the speedometer driven
hole cover sub-assembly.
4. REMOVE SPEEDOMETER SENSOR (w/o ABS)(a) Remove the bolt and speedometer sensor from the
transaxle case.
5. REMOVE BACK-UP LIGHT SWITCH ASSEMBLY(a) Separate the back-up light switch wire harness from
the 2 clamps.(b) Using SST, remove the back-up light switch
assembly and gasket from the manual transmissioncase.SST 09817-16011
6. REMOVE SELECTING BELL CRANK ASSEMBLY(a) Remove the 2 bolts and nut and remove the
selecting bell crank assembly from the manualtransmission case.
(b) Remove the control shift lever bush.
C080549
C080550
SST
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MX–42 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
7. REMOVE FLOOR SHIFT CONTROL SHIFT LEVER(a) Remove the nut and spring washer.
(b) Using a brass bar and a hammer, remove the lockpin.
(c) Remove the floor shift control shift lever.
8. REMOVE SHIFT LEVER DAMPER(a) Remove the nut and spring washer.
(b) Using a brass bar and a hammer, remove the lockpin.
(c) Remove the shift lever damper.
9. FIX MANUAL TRANSAXLE ASSEMBLY(a) Place the manual transaxle assembly on wooden
blocks.
C120748
C120747
C120746
C120745
Wooden
Blocks
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–43
10. REMOVE LOCK BALL ASSEMBLY NO.1(a) Remove lock ball assembly No. 1 from the manual
transmission case.
11. REMOVE SHIFT GATE PIN(a) Remove the shift gate pin and washer from the
transmission case.
12. REMOVE CONTROL SHAFT COVER(a) Remove the 4 bolts, control shaft cover and gasket
from the manual transmission case.
13. REMOVE CONTROL SHAFT COVER OIL SEAL(a) Using a screwdriver, remove the control shaft cover
oil seal from the control shaft cover.
14. REMOVE SHIFT AND SELECT LEVER SHAFTASSEMBLY(a) Remove the shift and select lever shaft assembly
from the transmission case.
C120744
C120743
C120742
C120741
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MX–44 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
15. REMOVE MANUAL TRANSMISSION CASE COVERSUB-ASSEMBLY(a) Remove the 9 bolts.
(b) Using a plastic hammer, carefully tap the projectionof the manual transmission case cover sub-assembly to remove the manual transmission casecover from the manual transmission case.NOTICE:Do not damage the manual transmission case.
16. REMOVE MANUAL TRANSMISSION OUTPUT SHAFTREAR SET NUT(a) Using a chisel and a hammer, loosen the staked
part of the manual transmission output shaft rear setnut.
(b) Engage the 2 gears simultaneously to lock thetransmission.
(c) Remove the manual transmission output shaft rearset nut.
(d) Disengage the 2 gears.
C080554
Projection PartC095189E01
C080341
Q006512
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–45
17. REMOVE GEAR SHIFT FORK NO.3(a) Remove the gear shift fork lock bolt from gear shift
fork No. 3.
(b) Remove transmission hub sleeve No. 3 with gearshift fork No. 3 from transmission clutch hub No. 3.
18. INSPECT 5TH GEAR THRUST CLEARANCE(a) Using a dial indicator, measure the 5th gear thrust
clearance.Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance:
0.55 mm (0.0217 in.)If the clearance exceeds the maximum, replacetransmission clutch hub No. 3, the 5th gear or input
shaft rear radial ball bearing.
19. INSPECT 5TH GEAR RADIAL CLEARANCE(a) Using a dial indicator, measure the 5th gear radial
clearance.Standard clearance:
KOYO made:0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:KOYO made:
0.058 mm (0.0023 in.)NSK made:
0.056 mm (0.0022 in.)If the clearance exceeds the maximum, replace the5th gear, 5th gear needle roller bearing or inputshaft.
C080342
C080343
C080344
C080345
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MX–46 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
20. REMOVE TRANSMISSION CLUTCH HUB NO.3(a) Using 2 screwdrivers and a hammer, tap out the
snap ring.HINT:Use a shop rag or piece of cloth to keep the snapring from flying off.
(b) Using SST, remove transmission clutch hub No. 3,the 5th gear and synchronizer ring No. 3 from theinput shaft.SST 09950-40011 (09951-04020, 09952-04010,
09953-04030, 09954-04010, 09955-04011),09950-60010 (09951-00180)
(c) Remove the 3 synchromesh shifting keys and 2synchromesh shifting key springs from transmissionclutch hub No. 3.
21. REMOVE 5TH GEAR NEEDLE ROLLER BEARING(a) Remove the 5th gear needle roller bearing and 5th
gear bearing spacer from the input shaft.
22. REMOVE 5TH DRIVEN GEAR(a) Using SST, remove the 5th driven gear from the
output shaft.SST 09950-30012 (09951-03010, 09953-03010,
09954-03010, 09955-03021), 09950-60010(09951-00180)
C080346
SST
C080347E01
D007737
C080348
SST
C080349E01
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–47
23. REMOVE BEARING RETAINER REAR(a) Remove the 5 bolts and bearing retainer rear from
the manual transmission case.
24. REMOVE OUTPUT SHAFT REAR BEARING HOLESNAP RING(a) Using a snap ring expander, remove the output
shaft rear bearing hole snap ring from the outputshaft.
25. REMOVE INPUT SHAFT REAR BEARING HOLESNAP RING(a) Using a snap ring expander, remove the input shaft
rear bearing hole snap ring from the input shaft.
26. REMOVE REVERSE IDLER GEAR SHAFT BOLT(a) Remove the reverse idler gear shaft bolt and
reverse idler gear shaft gasket from the manualtransmission case.
27. REMOVE SHIFT FORK SHAFT SHAFT SNAP RING(a) Using 2 screwdrivers and a hammer, tap out the
snap ring from gear shift fork shaft No. 2.HINT:Use a shop rag or piece of cloth to keep the snapring from flying off.
C080350E01
C080351
C080352
C067639
C080353
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MX–48 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
28. REMOVE SHIFT DETENT BALL(a) Using a hexagon wrench, remove the 2 shift detent
ball plugs from the manual transmission case.
(b) Using a magnetic finger, remove the 2 shift detentball spring seats No. 1, 2 shift detent ball springsand 2 shift detent balls from the manualtransmission case.
(c) Using a hexagon wrench, remove the shift detentball plug from the front transaxle case.
(d) Using a magnetic finger, remove the seat, springand ball from the front transaxle case.
29. REMOVE LOCK BALL ASSEMBLY NO.2(a) Using a hexagon wrench, remove lock ball
assembly No. 2 from the manual transmission case.
C067634
C067635
C080354
C080355
C080356
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MX–50 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
33. REMOVE GEAR SHIFT FORK SHAFT NO.2(a) Remove the 2 bolts from gear shift fork No. 2 and
gear shift head No. 1.
(b) Remove gear shift fork shaft No. 2 and gear shifthead No. 1 from the front transaxle case.
34. REMOVE GEAR SHIFT FORK SHAFT NO.1(a) Using 2 screwdrivers and a hammer, tap out the
snap ring.HINT:Use a shop rag or piece of cloth to keep the snapring from flying off.
(b) Remove the shift fork set bolt and gear shift forkshaft No. 1 from gear shift fork No. 1.
(c) Remove gear shift fork No. 1.
C080361
Gear Shift Fork
Shaft No. 2
Gear Shift
Head No. 1
C080362E01
C080363
Gear Shift Fork
Shaft No. 1
C080364E01
Gear Shift
Fork No. 1
C080365E01
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–51
35. REMOVE GEAR SHIFT FORK SHAFT NO.3(a) Using 2 screwdrivers and a hammer, tap out the
snap ring from gear shift fork shaft No. 3.HINT:Use a shop rag or piece of cloth to keep the snapring from flying off.
(b) Remove shift fork shaft No. 3 together with thereverse shift fork and gear shift fork No. 2 from themanual transaxle case.
(c) Using a magnetic finger, remove the 2 reverse shiftfork balls from the reverse shift fork.
(d) Using 2 screwdrivers and a hammer, tap the snapring out of shift fork shaft No. 3.HINT:Use a shop rag or piece of cloth to keep the snapring from flying off.
(e) Remove the reverse shift fork from gear shift forkshaft No. 3.
36. REMOVE INPUT SHAFT ASSEMBLY(a) Remove the input shaft assembly and output shaft
assembly from the front transaxle case.
C080366
Gear Shift Fork
Shaft No. 3
Reverse
Shift Fork
Gear Shift
Fork No. 2
C080367E01
C080368
C080369
C080586
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MX–52 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
37. REMOVE DIFFERENTIAL CASE ASSEMBLY(a) Remove the differential case assembly from the
front transaxle case.
38. REMOVE MANUAL TRANSAXLE CASE RECEIVER(a) Remove the bolt and manual transaxle case
receiver from the front transaxle case.
39. REMOVE REVERSE RESTRICT PIN ASSEMBLY(a) Using a hexagon wrench, remove the reverse
restrict pin plug from the manual transmission case.
(b) Using a pin punch (φ5 mm) and a hammer, drive outthe slotted spring pin and remove the reverserestrict pin assembly from the manual transmissioncase.
40. REMOVE OIL RECEIVER PIPE NO. 1(a) Remove the bolt and oil receiver pipe No. 1 from the
manual transmission case.NOTICE:Do not damage oil receiver pipe No. 1.
C067656
C067657
C080372
C080373
C067644
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–53
41. REMOVE OIL RECEIVER PIPE NO. 2(a) Remove the bolt and oil receiver pipe No. 2 from the
manual transmission case.NOTICE:Do not damage oil receiver pipe No. 2.
42. REMOVE BEARING LOCK PLATE(a) Remove the bolt and bearing lock plate from the
front transaxle case.
43. REMOVE TRANSMISSION MAGNET(a) Remove the transmission magnet from the front
transaxle case.
44. REMOVE INPUT SHAFT FRONT BEARING(a) Using SST, remove the input shaft front bearing
from the front transaxle case.SST 09612-65014 (09612-01050, 09612-01060)
45. REMOVE FRONT TRANSAXLE CASE OIL SEAL(a) Using a screwdriver, remove the front transaxle
case oil seal from the transaxle case.
C080374
C067658
C067659
SST
C081783E01
C095411
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MX–54 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
46. REMOVE OUTPUT SHAFT FRONT BEARING(a) Using SST, remove the output shaft front bearing
from the front transaxle case.SST 09308-00010NOTICE:Do not apply excessive force to the fronttransaxle case when installing it.
47. REMOVE OUTPUT SHAFT COVER(a) Remove the output shaft cover from the front
transaxle case.
48. REMOVE FR DIFFERENTIAL CASE FRONTTAPERED ROLLER BEARING(a) Using SST, remove the front differential case front
tapered roller bearing (outer race) and plate washerfrom the front transaxle case.SST 09612-65014 (09612-01040, 09612-01050)
(b) Using SST, remove the front differential case fronttapered roller bearing (inner race) from thedifferential case assembly.SST 09950-00020, 09950-00030, 09950-40011
(09957-04010), 09950-60010 (09951-00360)NOTICE:Do not damage the bearing.
49. REMOVE TRANSAXLE CASE OIL SEAL(a) Using SST and a hammer, remove the transaxle
case oil seal from the front transaxle case.SST 09950-60010 (09951-00530), 09950-70010
(09951-07150)
SST
C082141E01
C067719
SST
C081785E01
SST
G026414E01
SST
C081787E01
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–55
50. REMOVE FR DIFFERENTIAL CASE REAR TAPEREDROLLER BEARING(a) Using SST, remove the front differential case rear
tapered roller bearing (outer race) and plate washerfrom the transmission case.SST 09612-65014 (09612-01040, 09612-01050)
(b) Using SST, remove the front differential case reartapered roller bearing (inner race) from the frontdifferential case.SST 09950-40011 (09951-04010, 09952-04010,
09953-04020, 09954-04010, 09955-04061,09957-04010, 09958-04011), 09950-60010(09951-00360)
NOTICE:
Do not damage the bearing.
51. REMOVE TRANSMISSION CASE OIL SEAL(a) Using SST and a hammer, drive out the
transmission case oil seal from the manualtransmission case.SST 09950-60010 (09951-00530), 09950-70010
(09951-07150)
52. REMOVE SHIFT AND SELECT LEVER SHAFT OILSEAL(a) Using a screwdriver and hammer, remove the shift
and select lever shaft oil seal.
53. REMOVE SHIFT AND SELECT LEVER SHAFT SLIDEBALL BEARING(a) Using SST and a hammer, remove the shift and
select lever shaft slide ball bearing.SST 09950-60010 (09951-00220), 09950-70010
(09951-07200)
SST
C081788E01
SST
C082144E01
SST
C081789E01
C121110
SST
C121111E01
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MX–56 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
INSPECTION1. INSPECT SYNCHRONIZER RING NO.3
(a) Check for wear and damage.(b) Coat the 5th gear cone with gear oil.(c) Turn the synchronizer ring in one direction while
pushing it against the 5th gear cone.(d) Check that the ring locks.
If the synchronizer ring does not lock, replace thesynchronizer ring.
(e) Using a feeler gauge, measure the clearancebetween the synchronizer ring back and the gearspline end.Minimum clearance:
0.75 mm (0.0295 in.)If the clearance is less than the minimum, replacethe synchronizer ring.
2. INSPECT TRANSMISSION HUB SLEEVE NO.3(a) Check the sliding condition between transmission
hub sleeve No. 3 and transmission clutch hub No. 3.(b) Check that the edges of the transmission hub
sleeve No. 3 spline gear are not worn down.
(c) Using vernier calipers, measure the width of thetransmission hub sleeve No. 3 groove (A) and thethickness of the claw part on the gear shift fork No. 3(B), and calculate the clearance.Standard clearance (A - B):
0.3 to 0.5 mm (0.012 to 0.0020 in.)If the clearance exceeds the standard, replacetransmission hub sleeve No. 3 and gear shift forkNo. 3.
C067848
C067850
C067978
A
B
Clearance = (A - B)C080375E01
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–57
3. INSPECT 5TH GEAR(a) Using a caliper gauge, measure the inside diameter
of the 5th gear.Standard inside diameter:
29.915 to 29.931 mm (1.1778 to 1.1783 in.)Maximum inside diameter:
29.931 mm (1.1783 in.)If the inside diameter exceeds the maximum,replace the 5th gear.
4. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY(a) Using a caliper gauge, inspect the reverse idle gear.
Standard inside diameter:18.040 to 18.058 mm (0.7102 to 0.7109 in.)
Maximum inside diameter:18.058 mm (0.7109 in.)
If the inside diameter exceeds the maximum,replace the reverse idler gear sub-assembly.
(b) Using a micrometer, inspect the reverse idler gearshaft as shown in the illustration.Standard outer diameter:
17.966 to 17.984 mm (0.7073 to 0.7080 in.)Minimum outer diameter:
17.966 mm (0.7073 in.)If the outer diameter is less than the minimum,replace the reverse idler gear shaft.
REASSEMBLY1. INSTALL OUTPUT SHAFT COVER
(a) Coat the output shaft cover with MP grease andinstall it onto the front transaxle case.NOTICE:Insert the output shaft cover projection into thecase side hollow.
2. INSTALL OUTPUT SHAFT FRONT BEARING(a) Coat a new output shaft front bearing with gear oil.
Using SST and a press, install it onto the fronttransaxle case.SST 09950-60010 (09951-00550), 09950-70010
(09951-07150)NOTICE:• Install the new bearing in the correct
direction, as shown in the illustration.
C067975
C067846E01
Case Cover
C095191E01
SST
C080376E01
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MX–58 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
• When replacing the output shaft frontbearing, replace the output shaft frontbearing inner race at the same time.
3. INSTALL FRONT TRANSAXLE CASE OIL SEAL(a) Using SST and a hammer, install a new front
transaxle case oil seal onto the front transalxe case.SST 09950-60010 (09951-00370), 09950-70010
(09951-07150)Drive in depth:
15.6 to 16.0 mm (0.6141 to 0.6299 in.)(b) Coat the lip of the front transaxle case oil seal with
MP grease.
4. INSTALL INPUT SHAFT FRONT BEARING(a) Coat a new input shaft front bearing with gear oil,
and using SST and a press, install it onto the fronttransaxle case.SST 09950-60010 (09951-00420), 09950-70010
(09951-07150)Drive in depth:
0 to 0.3 mm (0 to 0.0118 in.)
5. INSTALL SHIFT AND SELECT LEVER SHAFT SLIDEBALL BEARING(a) Using SST and a hammer, install the shift and select
lever shaft slide ball bearing onto the transmissioncase.SST 09950-60010 (09951-00220), 09950-70010
(09951-07100)Drive in depth:
0 to 0.5 mm (0 to 0.0020 in.)
6. INSTALL SHIFT AND SELECT LEVER SHAFT OILSEAL(a) Using SST, install the shift and select lever shaft oil
seal onto the transmission case.SST 09950-70010 (09951-07150), 09950-60010
(09951-00240)Drive in depth:
9.7 to 10.3 mm (0.382 to 0.406 in.)
SST
C081790E01
SST
C081791E01
SST
C121112E01
SST
C120752E01
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–59
7. INSTALL FR DIFFERENTIAL CASE FRONT TAPEREDROLLER BEARING(a) Using SST and a press, install the front differential
case front tapered roller bearing (inner race) ontothe front differential case.SST 09350-32014 (09351-32120), 09950-60010
(09951-00530)
(b) Using SST and a press, install the front differentialcase front tapered roller bearing (outer race)together with the plate washer onto the fronttransaxle case.SST 09950-60020 (09951-00680), 09950-70010
(09951-07150)
8. INSTALL FR DIFFERENTIAL CASE REAR TAPEREDROLLER BEARING(a) Using SST and a press, install the front differential
case rear tapered roller bearing (inner race) ontothe differential case.SST 09350-32014 (09351-32120), 09950-60010
(09951-00530)
(b) Using SST and a press, install the front differentialcase rear tapered roller bearing (outer race) withplate washer onto the transmission case.SST 09309-36010, 09950-60020 (09951-00710),
09950-70010 (09951-07150)HINT:Use a plate washer of the same thickness as theremoved one.
9. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD(a) Coat the differential case assembly with gear oil,
and install it onto the front transaxle case.(b) Install the manual transmission case with the 16
bolts.Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
SST
C082146E01
SST
C080379E01
SST
C082147E01
SST
C081792E01
C067656
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MX–60 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
(c) Using SST and a torque wrench, turn the differentialcase assembly to the right and left 2 or 3 times toallow the bearings to settle.SST 09564-32011
(d) Using SST and a torque wrench, measure thepreload.SST 09564-32011Preload (at starting):
New bearing:0.78 to 1.57 N*m (7.95 to 16.0 kgf*cm, 6.9 to13.89 in.*lbf)
Used bearing:
0.49 to 0.98 N*m (5.0 to 10.0 kgf*cm, 4.34 to8.67 in.*lbf)If the preload is outside the specifications, selectanother plate washer.Plate washer thickness
HINT:The preload changes by approximately 0.3 to 0.4N*m (3 to 4 kgf*cm, 2.6 to 3.5 in.*lbf) per each 0.05mm (0.0020 in.) change in plate washer thickness.
(e) Remove the 16 bolts and the manual transmission
case.(f) Remove the differential case assembly from thefront transaxle case.
SST
C081793E01
SST
C081793E01
MarkThickness mm
(in.)Mark
Thickness mm
(in.)
AA 2.10 (0.0827) LL 2.60 (0.1024)
BB 2.15 (0.0846) MM 2.65 (0.1043)
CC 2.20 (0.0866) NN 2.70 (0.1063)
DD 2.25 (0.0886) PP 2.75 (0.1083)
EE 2.30 (0.0906) QQ 2.80 (0.1102)
FF 2.35 (0.0925) RR 2.85 (0.1122)
GG 2.40 (0.0945) SS 2.90 (0.1142)
HH 2.45 (0.0965) TT 2.95 (0.1161)
JJ 2.50 (0.0984) UU 3.00 (0.1181)
KK 2.55 (0.1004) - -
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–61
10. INSTALL TRANSMISSION CASE OIL SEAL(a) Using SST and a hammer, install a new
transmission case oil seal onto the manualtransmission case.SST 09316-60011 (09316-00011)Drive in depth:
9.6 to 10.2 mm (0.378 to 0.402 in.)(b) Coat the lip of the front transmission case oil seal
with MP grease.
11. INSTALL TRANSAXLE CASE OIL SEAL(a) Using SST and a hammer, install a new transaxle
case oil seal onto the front transaxle case.Drive in depth:
1.6 to2.2 mm (0.063 to 0.087 in.)SST 09710-20011 (09710-06071), 09950-70010
(09951-07150)(b) Coat the lip of the transaxle case oil seal with MP
grease.
12. INSTALL TRANSMISSION MAGNET(a) Clean the transmission magnet and install it onto
the front transaxle case.
13. INSTALL BEARING LOCK PLATE(a) Install the bearing lock plate onto the front transaxle
case with the bolt.Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
14. INSTALL OIL RECEIVER PIPE NO. 1(a) Install oil receiver pipe No. 1 onto the manual
transmission case with the bolt.Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)NOTICE:• Do not deform oil receiver pipe No. 1.• Install the oil receiver pipe No. 1 while
holding it against the manual transmissioncase, as shown in the illustration.
SST
C080381E01
SST
C080382E01
C067659
C067658
C068380
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MX–62 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
15. INSTALL OIL RECEIVER PIPE NO. 2(a) Install the oil receiver pipe No. 2 onto the manual
transmission case with the bolt.Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)NOTICE:• Do not deform oil receiver pipe No. 2.• Install the oil receiver pipe No. 2 while
holding it against the manual transmissioncase, as shown in the illustration.
16. INSTALL REVERSE RESTRICT PIN ASSEMBLY(a) Install the reverse restrict pin assembly onto the
manual transmission case.NOTICE:Set the reverse restrict pin assembly in thecorrect orientation.
(b) Using a pin punch (φ5 mm) and a hammer, installthe slotted pin onto the reverse restrict pinassembly.Drive in depth:
15.5 to 16.5 mm (0.6102 to 0.6496 in.)
(c) Apply sealant to the reverse restrict pin plug.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
(d) Using a hexagon wrench and a torque wrench,install the reverse restrict pin plug onto the manualtransmission case.Torque: 13 N*m (130 kgf*cm, 9.3 ft.*lbf)
17. INSTALL MANUAL TRANSAXLE CASE RECEIVER(a) Install the manual transaxle case receiver onto the
front transaxle case with the bolt.Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
C080432
C080383
C080384
C120732
C067657
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–63
18. INSTALL DIFFERENTIAL CASE ASSEMBLY(a) Coat the differential case tapered roller bearing with
gear oil and install the differential case assemblyonto the front transaxle case.
19. INSTALL INPUT SHAFT ASSEMBLY(a) Coat the sliding and rotating surfaces of the input
and output shafts with gear oil and install them ontothe transaxle case.
20. INSTALL REVERSE IDLER GEAR SUB-ASSEMBLY(a) Coat the reverse idler gear sub-assembly, thrust
washer and reverse idler gear shaft with gear oiland install them as shown in the illustration.HINT:Align the mark on the reverse idler gear shaft withthe bolt hole shown in the illustration.
21. INSTALL GEAR SHIFT FORK SHAFT NO.1(a) Coat gear shift fork No. 1 and gear shift fork No. 2
with gear oil and install them.
(b) Coat gear shift fork shaft No. 1 with gear oil andinstall it.
(c) Apply sealant to the shift fork set bolt.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
(d) Install the shift fork set bolt.Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
C067656
C080586
Align Alignment Mark
C080386E03
Gear Shift
Fork No. 2
Gear Shift
Fork No. 1
C080387E01
Gear Shift Fork
Shaft No. 1
C080388E01
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MX–64 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
(e) Using a brass bar and a hammer, install a new shaftsnap ring onto gear shift fork shaft No. 1.
22. INSTALL GEAR SHIFT FORK SHAFT NO.3(a) Coat the 2 shift fork balls with MP grease and install
them onto the reverse shift fork.(b) Install the reverse shift fork onto gear shift fork shaft
No. 3.
(c) Using a brass bar and a hammer, install 2 new shiftfork shaft snap rings onto shift fork shaft No. 3.
(d) Coat gear shift fork shaft No. 3 with gear oil andinstall it.
C080389
C080450
C080391
C080392
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–65
23. INSTALL GEAR SHIFT FORK SHAFT NO.2(a) Coat gear shift head No. 1 and gear shift fork shaft
No. 2 with gear oil and install them.NOTICE:To avoid interference by the 2 shift fork balls, liftup gear shift fork shaft No. 3 to the positionshown in the illustration.
(b) Coat the 2 shift lock bolts with sealant and installthem onto gear shift fork No. 2 and shift head No. 1.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
24. INSTALL REVERSE SHIFT ARM BRACKETASSEMBLY(a) Install the reverse shift arm bracket assembly onto
the front transaxle case with 2 bolts.Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
25. INSTALL MANUAL TRANSMISSION CASE(a) Apply FIPG to the manual transmission case, as
shown in the illustration.FIPG:
Toyota Genuine Seal Packing 1281, ThreeBond 1281 or Equivalent
NOTICE:Assemble the parts within 10 minutes ofapplication. Otherwise, the packing (FIPG)material must be removed and reapplied.
C117123
C080361
C080360
FIPG
C082142E01
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MX–66 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
(b) Install the 13 bolts onto the manual transmissionside.Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
(c) Install the 3 bolts onto the manual transaxle side.Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
26. INSTALL REVERSE IDLER GEAR SHAFT BOLT(a) Coat the reverse idler gear shaft bolt with sealant
and install it with a new gasket.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
27. INSTALL LOCK BALL ASSEMBLY NO.2(a) Coat lock ball assembly No. 2 with sealant and
install it with a hexagon wrench.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)
28. INSTALL SHIFT DETENT BALL(a) Install the 2 shift detent balls, 2 shift detent ball
springs and 2 shift detent ball spring seats No. 1onto the manual transmission case.
C080358
C080357
C067639
C080356
D032759
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–67
(b) Coat the 2 shift detent ball plugs with sealant andinstall them using a hexagon wrench.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
(c) Install the shift detent ball, shift detent ballcompression spring and shift detent ball spring seatNo. 1 onto the front transaxle case.
(d) Coat the shift detent ball plug with sealant andinstall it using a hexagon wrench.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)
29. INSTALL INPUT SHAFT REAR BEARING HOLE SNAPRING(a) Using a snap ring expander, install the input shaft
rear bearing hole snap ring onto the input shaft.
30. INSTALL OUTPUT SHAFT REAR BEARING HOLESNAP RING(a) Using a snap ring expander, install the output shaft
rear bearing hole snap ring onto the output shaft.
C067634
C080393
C080354
C080352
C080351
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MX–68 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
31. INSTALL SHIFT FORK SHAFT SHAFT SNAP RING(a) Using a brass bar and a hammer, install a new shift
fork shaft shaft snap ring onto the shift fork shaft No.2.
32. INSTALL BEARING RETAINER REAR(a) Coat the 5 bolts with sealant, and install the bearing
retainer rear onto the manual transmission casewith the 5 bolts.Torque: 27 N*m (280 kgf*cm, 20 ft.*lbf)
33. INSTALL 5TH DRIVEN GEAR(a) Using SST, install the 5th driven gear onto the
output shaft.SST 09309-12020
34. INSTALL 5TH GEAR NEEDLE ROLLER BEARING(a) Coat the 5th gear needle roller bearing and 5th gear
bearing spacer with gear oil, and install them ontothe input shaft.
35. INSTALL 5TH GEAR(a) Coat the 5th gear with gear oil and install it onto the
input shaft.
C080394
C080350
SST
SST
C095786E03
C080348
C080396
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–69
36. INSTALL SYNCHRONIZER RING NO.3(a) Coat synchronizer ring No. 3 with gear oil and install
it onto the 5th gear.
37. INSTALL TRANSMISSION CLUTCH HUB NO.3(a) Install the 3 synchromesh shifting keys and 2
synchromesh shifting key springs onto thetransmission clutch hub No. 3, as shown in theillustration.NOTICE:Do not set the 2 shifting key spring openings inthe same position.
(b) Using SST and a hammer, install transmissionclutch hub No. 3 onto the input shaft.SST 09636-20010NOTICE:• Do not install transmission clutch hub No. 3
in the wrong direction.• Install the transmission clutch hub No. 3 with
the synchronizer ring No. 3 key groove andsynchromesh shifting key No. 3 aligned.
• Check that the 5th gear is rotating.• Place a suitable sized wooden block to
support the input shaft.
(c) Select a clutch hub No. 3 shaft snap ring that willallow minimum axial play.Clearance:
0.1 mm or lessSnap ring thickness
D031112
Engine
SideC080398E01
Key Position
Wooden Block
SST
C080399E02
C080400
MarkThickness mm
(in.)Mark
Thickness mm
(in.)
A 2.25 (0.0886) E 2.49 (0.0980)
B 2.31 (0.0909) F 2.55 (0.1004)
C 2.37 (0.0933) G 2.61 (0.1028)
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MX–70 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
(d) Using a brass bar and a hammer, install the snapring onto the input shaft.
38. INSPECT 5TH GEAR THRUST CLEARANCE(a) Using a dial indicator, measure the 5th gear thrust
clearance.Standard clearance:
0.1 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance:
0.55 mm (0.0217 in.)If the clearance exceeds the maximum, replacetransmission clutch hub No. 3, the 5th gear or inputshaft rear radial ball bearing.
39. INSPECT 5TH GEAR RADIAL CLEARANCE(a) Using a dial indicator, measure 5th gear radial
clearance.Standard clearance:
KOYO made:0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:KOYO made:
0.058 mm (0.0023 in.)NSK made:
0.056 mm (0.0022 in.)If the clearance exceeds the maximum, replace the
5th gear, 5th gear needle roller bearing or inputshaft.
40. INSTALL GEAR SHIFT FORK NO.3(a) Coat transmission clutch hub sleeve No. 3 with gear
oil and install it together with gear shift fork No. 3onto transmission clutch hub No. 3.HINT:Set the transmission clutch hub No. 3 in the correctorientation.
(b) Coat the gear shift fork lock bolt with sealant, andinstall it onto gear shift fork No. 3.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
D 2.43 (0.0957) - -
MarkThickness mm
(in.)Mark
Thickness mm
(in.)
C080344
C080345
C080401
C080402
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–71
41. INSTALL MANUAL TRANSMISSION OUTPUT SHAFTREAR SET NUT(a) Engage the 2 gears simultaneously to lock the
transmission.(b) Coat a new manual transmission output shaft rear
set nut with sealant.Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
(c) Install the new manual transmission output shaftrear set nut.Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf)
(d) Using a chisel and a hammer, stake the manualtransmission output shaft rear set nut.
(e) Disengage the 2 gears.
42. INSTALL MANUAL TRANSMISSION CASE COVERSUB-ASSEMBLY(a) Apply FIPG to the manual transaxle case cover sub-
assembly as shown in the illustration.FIPG:
Toyota Genuine Seal Packing 1281, ThreeBond 1281 or Equivalent
NOTICE:
Assemble the parts within 10 minutes ofapplication. Otherwise, the packing (FIPG)material must be removed and reapplied.
(b) Install the manual transmission case cover sub-assembly onto the manual transmission case withthe 9 bolts.Torque: 18 N*m (185 kgf*cm, 14 ft.*lbf)
C080403
C080404
FIPG
C080556E02
C080554
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MX–72 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
43. INSTALL SHIFT AND SELECT LEVER SHAFTASSEMBLY(a) Coat the shift and select lever shaft assembly with
gear oil, and install it onto the transmission case.
44. INSTALL CONTROL SHAFT COVER OIL SEAL(a) Using SST and a hammer, install a new control shaft
cover oil seal onto the control shaft cover.Drive in depth:
0.2 to 1.2 mm (0.0079 to 0.0472 in.)SST 09950-60010 (09951-00280), 09950-70010
(09951-07150)(b) Coat the control shaft cover oil seal with MP grease.
45. INSTALL CONTROL SHAFT COVER(a) Coat the 4 bolts with sealant. Install a new gasket
and control shaft cover onto the manualtransmission case with the 4 bolts.Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
NOTICE:
Set the claws of the shift interlock plate into theshift head part of the gear shift fork shaftsecurely.
46. INSTALL SHIFT GATE PIN(a) Coat the shift gate pin with sealant.(b) Install the washer and shift gate pin.
Torque: 11 N*m (112 kgf*cm, 8.1 ft.*lbf)Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
C120740
SST
C120731E01
C120742
C120743
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C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT MX–73
47. INSTALL LOCK BALL ASSEMBLY NO.1(a) Coat lock ball assembly No. 1 with sealant, install it
onto the manual transmission case.Torque: 29 N*m (300 kgf*cm, 22 ft.*lbf)Sealant:
Toyota Genuine Adhesive 1344, Three Bond1344 or Equivalent
48. INSTALL SHIFT LEVER DAMPER(a) Install the dust boot onto the control shaft cover.(b) Install the shift lever damper with the lock pin onto
the shift and select lever shaft assembly.(c) Install the spring washer with the nut.
Torque: 12 N*m (120 kgf*cm, 8.7 ft.*lbf)
49. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER(a) Install the dust boot onto the shift and select lever
shaft oil seal.(b) Install the floor shift control shift lever with the lock
pin onto the shift and select lever shaft assembly.(c) Install the spring washer with the nut.
Torque: 12 N*m (120 kgf*cm, 8.7 ft.*lbf)
50. INSTALL SELECTING BELL CRANK ASSEMBLY(a) Install the selecting bell crank assembly together
with the control shift lever bush onto the manualtransmission case with the 2 bolts and nut.Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) for bolt
12 N*m (120 kgf*cm, 8.7 ft.*lbf) for nutNOTICE:Apply MP grease to the inside circumferentialsurface of the control shift lever bush.
51. INSTALL BACK-UP LIGHT SWITCH ASSEMBLY(a) Using SST, install the back-up light switch assembly
onto the manual transmission case with a newgasket.SST 09817-16011Torque: 40 N*m (410 kgf*cm, 30 ft.*lbf)
(b) Install the back-up light switch wire harness into the2 clamps.
52. INSTALL SPEEDOMETER SENSOR (w/o ABS)(a) Install a new O-ring onto the speedometer sensor.
C120744
C120746
C120748
C120750
SST
C120749E01
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MX–74 C50 MANUAL TRANSAXLE – MANUAL TRANSAXLE UNIT
MX
(b) Install the speedometer sensor onto the transaxlecase with the bolt.Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
53. INSTALL SPEEDOMETER DRIVEN HOLE COVERSUB-ASSEMBLY(a) Install a new O-ring onto the speedometer driven
hole cover sub-assembly.
(b) Install the speedometer driven hole cover sub-assembly onto the manual transaxle case with thebolt.Torque: 11 N*m (115 kgf*cm, 8.3 ft.*lbf)
54. INSTALL MANUAL TRANSMISSION FILLER PLUG(a) Install the manual transmission filler plug onto the
manual transmission case with a new gasket.Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
55. INSTALL DRAIN PLUG SUB-ASSEMBLY(a) Install the drain plug onto the manual transmission
case with a new gasket.Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
C080549
C080550
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C50 MANUAL TRANSAXLE – INPUT SHAFT MX–75
TRANSMISSIONC50MANUAL TRANSAXLE
INPUT SHAFT
COMPONENTS
4TH GEAR
3RD GEAR
4TH GEAR NEEDLE
ROLLER BEARING
INPUT SHAFT REAR RADIAL BALL BEARING
TRANSMISSION HUB SLEEVE NO.2
INPUT SHAFT
SYNCHROMESH SHIFTING KEY SPRING
4TH GEAR BEARING SPACER
SNAP RING
SNAP RING
3RD GEAR SYNCHRONIZER RING
SYNCHROMESH SHIFTING KEY
3RD GEAR NEEDLE ROLLER BEARING
4TH GEAR SYNCHRONIZER RING
TRANSMISSION CLUTCH HUB NO.2
x3
x3
C118354E01
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MX–76 C50 MANUAL TRANSAXLE – INPUT SHAFT
MX
DISASSEMBLY1. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 4th gear thrustclearance.Standard clearance:
0.1 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance:
0.55 mm (0.0217 in.)If the clearance exceeds the maximum, replacetransmission clutch hub No. 2, the 4th gear or inputshaft rear radial ball bearing.
2. INSPECT 3RD GEAR THRUST CLEARANCE(a) Using a dial gauge, measure the 3rd gear thrust
clearance.Standard clearance:
0.1 to 0.35 mm (0.0039 to 0.0138 in.)Maximum clearance:
0.35 mm (0.0138 in.)
If the clearance exceeds the maximum, replacetransmission clutch hub No. 2, the 3rd gear or inputshaft.
3. INSPECT 4TH GEAR RADIAL CLEARANCE(a) Using a dial indicator, measure the 4th gear radial
clearance between the gear and shaft.Standard clearance:
0.009 to 0.050 mm (0.0004 to 0.0020 in.)Maximum clearance:
0.050 mm (0.0020 in.)If the clearance exceeds the maximum, replace the
4th gear, 4th gear needle roller bearing or inputshaft.
4. INSPECT 3RD GEAR RADIAL CLEARANCE(a) Using a dial gauge, measure the 3rd gear radial
clearance between the gear and shaft.Standard clearance:
KOYO made bearing:0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made bearing:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:
KOYO made:0.058 mm (0.0023 in.)
NSK made:0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the3rd gear, 3rd gear needle roller bearing or inputshaft.
C080557
C067816
C080558
C067815
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C50 MANUAL TRANSAXLE – INPUT SHAFT MX–77
5. REMOVE 4TH GEAR(a) Using 2 screwdrivers and a hammer, remove the
input shaft rear bearing shaft snap ring from theinput shaft.HINT:Use a shop rag or piece of cloth to keep the snapring from flying off.
(b) Using SST and a press, remove the input shaft rearradial ball bearing and 4th gear from the input shaft.SST 09950-00020HINT:• Do not tighten SST excessively.• Support the input shaft assembly by hand to
prevent it from dropping off.
6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING(a) Remove the 4th gear needle roller bearing and 4th
gear bearing spacer from the input shaft.
7. REMOVE 4TH GEAR SYNCHRONIZER RING(a) Remove synchronizer ring No. 2 from transmission
clutch hub No. 2.
8. REMOVE 3RD GEAR(a) Using 2 screwdrivers and a hammer, remove the
clutch hub No. 2 setting shaft snap ring from theinput shaft.HINT:Use a shop rag or piece of cloth to keep the snapring from flying off.
C080559
SST
Q004983E01
C080560
C080561
C067821
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MX–78 C50 MANUAL TRANSAXLE – INPUT SHAFT
MX
(b) Using SST and a press, remove transmission clutchhub No. 2 and the 3rd gear from the input shaft.SST 09950-00020NOTICE:• Do not tighten SST excessively.• Support the input shaft by hand to prevent it
from dropping off.
9. REMOVE 3RD GEAR SYNCHRONIZER RING(a) Remove synchronizer ring No. 2 from the 3rd gear.
10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING(a) Remove the 3rd gear needle roller bearing from the
input shaft.
11. REMOVE TRANSMISSION HUB SLEEVE NO.2(a) Remove transmission hub sleeve No. 2, the 3
shifting keys and 3 shifting key springs fromtransmission clutch hub No. 2.NOTICE:Use a shop rag or piece of cloth to keep theshifting key and shifting key spring from flyingoff.
INSPECTION1. INSPECT INPUT SHAFT
(a) Using a dial gauge, check the input shaft runout.Maximum runout:
0.015 mm (0.0006 in.)If the runout exceeds the maximum, replace theinput shaft.
SST
CM00064E01
C080455
C067823
C067832
CM00013
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C50 MANUAL TRANSAXLE – INPUT SHAFT MX–79
(b) Using a micrometer, measure the outer diameter ofthe input shaft journal surface, at the locationsindicated.Standard outer diameter:
Part A:24.885 to 24.900 mm (0.9797 to 0.9803 in.)
Part B:28.991 to 29.006 mm (1.1414 to 1.1420 in.)
Part C:30.985 to 31.000 mm (1.2198 to 1.2204 in.)
Part D:24.985 to 25.000 mm (0.9836 to 0.9842 in.)
Minimum outer diameter:Part A:
24.885 mm (0.9797 in.)Part B:
28.991 mm (1.1414 in.)Part C:
30.985 mm (1.2198 in.)
Part D:24.985 mm (0.9836 in.)If the outer diameters are less than the minimums,replace the input shaft.
2. INSPECT 4TH GEAR(a) Using a cylinder gauge, measure the inside
diameter of the 4th gear.Standard inside diameter:
34.015 to 34.031 mm (1.3391 to 1.3398 in.)Maximum inside diameter:
34.031 mm (1.3398 in.)If the inside diameter exceeds the maximum,
replace the 4th gear.
3. INSPECT 3RD GEAR(a) Using a cylinder gauge, measure the inside
diameter of the 3rd gear.Standard inside diameter:
36.015 to 36.031 mm (1.4179 to 1.4185 in.)Maximum inside diameter:
36.031 mm (1.4185 in.)If the inside diameter exceeds the maximum,replace the 3rd gear.
A B C D
C080562E02
C067826
C067827
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MX–80 C50 MANUAL TRANSAXLE – INPUT SHAFT
MX
4. INSPECT 4TH GEAR SYNCHRONIZER RING(a) Check for wear and damage.(b) Coat the 4th gear cone with gear oil.(c) Turn the synchronizer ring in one direction while
pushing it against the 4th gear cone.(d) Check that the ring locks.
If the synchronizer outer ring does not lock, replacethe synchronizer ring.
(e) Using a feeler gauge, measure the clearancebetween the synchronizer ring back and the gearspline end.Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0649 in.)Minimum clearance:
0.75 mm (0.0295 in.)If the clearance is less than the minimum, replace
the synchronizer ring.
5. INSPECT 3RD GEAR SYNCHRONIZER RING(a) Check for wear and damage.(b) Coat the 3rd gear cone with gear oil.(c) Turn the synchronizer ring in one direction while
pushing it against the 3rd gear cone.(d) Check that the ring locks.
If the synchronizer outer ring does not lock, replacethe synchronizer ring.
(e) Using a feeler gauge, measure the clearancebetween the synchronizer ring back and the gearspline end.Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)Minimum clearance:
0.75 mm (0.0295 in.)If the clearance is less than the minimum, replacethe synchronizer ring.
6. INSPECT TRANSMISSION HUB SLEEVE NO.2(a) Check the sliding condition between transmission
hub sleeve No. 2 and transmission clutch hub No. 2.(b) Check that the edges of the transmission hub
sleeve No. 2 spline gear are not worn down.
C080457
C080458
C080459
C080460
C067843
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C50 MANUAL TRANSAXLE – INPUT SHAFT MX–81
(c) Using vernier calipers, measure the width of thetransmission hub sleeve No. 2 groove (B) and thethickness of the claw part on gear shift fork No. 2(A), and calculate the clearance.Standard clearance (B - A):
0.15 to 0.35 mm (0.0059 to 0.0137 in.)If the clearance is outside the specifications, replacetransmission hub sleeve No. 2 and gear shift forkNo. 2.
REASSEMBLY1. INSTALL TRANSMISSION HUB SLEEVE NO.2
(a) Coat transmission hub sleeve No. 2 with gear oil,and install it to transmission clutch hub No. 2.NOTICE:Orient the transmission hub sleeve No.2 andtransmission clutch hub No.2 correctly.
(b) Using a screwdriver, install the 3 synchromesh keysprings with 3 synchromesh shifting keys onto
transmission clutch hub No. 2.
2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING(a) Coat the 3rd gear needle roller bearing with gear oil
and install it onto the input shaft.
3. INSTALL 3RD GEAR(a) Coat the 3rd gear with gear oil and install it onto the
input shaft.
B
A
Clearance = B - A
C067842E02
C069660
C067823
D032763
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MX–82 C50 MANUAL TRANSAXLE – INPUT SHAFT
MX
4. INSTALL 3RD GEAR SYNCHRONIZER RING(a) Coat the 3rd gear synchronizer ring with gear oil
and install it onto the 3rd gear.
5. INSTALL TRANSMISSION CLUTCH HUB NO.2(a) Using SST and a press, install transmission clutch
hub No. 2 onto the input shaft.SST 09316-60011 (09316-00021)NOTICE:Fit the synchromesh shifting key into the grooveof the synchronizer ring correctly.
(b) Select a snap ring that will allow minimum axial play.Standard clearance:
0.1 mm (0.0039 in.) or less.Snap ring thickness
(c) Using a brass bar and a hammer, install the snapring onto the input shaft.
6. INSTALL 4TH GEAR SYNCHRONIZER RING(a) Coat the 4th gear synchronizer ring with gear oil and
install it onto transmission clutch hub No. 2.
Key Position
For 3rd Gear
D031159E01
SST
C080563E01
C067837
MarkThickness mm
(in.)Mark
Thickness mm
(in.)
0 2.30 (0.0906) 3 2.48 (0.0976)
1 2.36 (0.0929) 4 2.54 (0.1000)
2 2.42 (0.0953) 5 2.60 (0.1024)
Key Position
For 4th Gear
C080464E02
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C50 MANUAL TRANSAXLE – INPUT SHAFT MX–83
7. INSTALL 4TH GEAR NEEDLE ROLLER BEARING(a) Coat the 4th gear needle roller bearing and 4th gear
bearing spacer with gear oil and install them ontotransmission clutch hub No. 2.
8. INSTALL 4TH GEAR(a) Coat the 4th gear with gear oil and install it onto the
input shaft.
9. INSTALL INPUT SHAFT REAR RADIAL BALLBEARING(a) Using SST and a press, install the input shaft rear
radial ball bearing onto the input shaft.SST 09608-04031
(b) Select a snap ring that will allow minimum axial play.Standard clearance:
0.1 mm (0.0039 in.) or lessSnap ring thickness
(c) Using a brass bar and a hammer, install the snapring onto the input shaft.NOTICE:Do not damage the journal surface of the snapring.
C080560
C080564
SST
C080565E01
C080566
MarkThickness mm
(in.)Mark
Thickness mm
(in.)
A 2.29 (0.0901) D 2.47 (0.0972)
B 2.35 (0.0925) E 2.53 (0.0996)
C 2.41 (0.0948) F 2.59 (0.1019)
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MX–84 C50 MANUAL TRANSAXLE – INPUT SHAFT
MX
10. INSPECT 3RD GEAR RADIAL CLEARANCE(a) Using a dial gauge, measure the 3rd gear radial
clearance.Standard clearance:
KOYO made:0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:KOYO made:
0.058 mm (0.0023 in.)NSK made:
0.056 mm (0.0022 in.)If the clearance exceeds the maximum, replace the3rd gear, 3rd gear needle roller bearing or inputshaft.
11. INSPECT 4TH GEAR RADIAL CLEARANCE(a) Using a dial gauge, measure the 4th gear radial
clearance.
Standard clearance:0.009 to 0.050 mm (0.0004 to 0.0020 in.)
Maximum clearance:0.050 mm (0.0020 in.)
If the clearance exceeds the maximum, replace the4th gear, 4th gear needle roller bearing or inputshaft.
12. INSPECT 3RD GEAR THRUST CLEARANCE(a) Using a dial gauge, measure the 3rd thrust
clearance.Standard clearance:
0.1 to 0.35 mm (0.0039 to 0.0138 in.)Maximum clearance:
0.35 mm (0.0138 in.)If the clearance exceeds the maximum, replacetransmission clutch hub No. 2, the 3rd gear or inputshaft.
13. INSPECT 4TH GEAR THRUST CLEARANCE(a) Using a feeler gauge, measure the 4th thrust
clearance.Standard clearance:
0.1 to 0.55 mm (0.0039 to 0.0217 in.)
Maximum clearance:0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replacetransmission clutch hub No. 2, the 4th gear or inputshaft rear radial ball bearing.
C067815
C067816
C080557
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C50 MANUAL TRANSAXLE – OUTPUT SHAFT MX–85
TRANSMISSIONC50MANUAL TRANSAXLE
OUTPUT SHAFT
COMPONENTS
1ST GEAR
1ST GEAR THRUST
WASHER PIN OR BALL
2ND GEAR
2ND GEAR NEEDLE
ROLLER BEARING3RD DRIVEN GEAR
4TH DRIVEN GEAR
OUTPUT SHAFT REAR BEARING
REVERSE GEAR
SYNCHRONIZER RING
NO.1 (FOR 1ST GEAR)
SYNCHRONIZER RING
NO.1 (FOR 2ND GEAR)
TRANSMISSION
CLUTCH HUB NO.1
OUTPUT SHAFT
SNAP RING
OUTPUT GEAR SPACER
1ST GEAR NEEDLE ROLLER BEARING
SYNCHROMESH SHIFTING KEY
SYNCHROMESH
SHIFTING KEY SPRING
1ST GEAR THRUST WASHER
2ND GEAR
BEARING SPACER
Apply MP grease
x3
x3
C118356E01
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MX–86 C50 MANUAL TRANSAXLE – OUTPUT SHAFT
MX
DISASSEMBLY1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 1st gear thrustclearance.Standard clearance:
0.10 to 0.40 mm (0.0039 to 0.0157 in.)Maximum clearance:
0.40 mm (0.0157 in.)If the clearance exceeds the maximum, replace the1st gear thrust washer, 1st gear or transmissionclutch hub No. 1.
2. INSPECT 2ND GEAR THRUST CLEARANCE(a) Using a dial gauge, measure the 2nd gear thrust
clearance.Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance:
0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replacetransmission clutch hub No. 1, 2nd gear or 3rddriven gear.
3. INSPECT 1ST GEAR RADIAL CLEARANCE(a) Using a dial gauge, measure the 1st gear radial
clearance between the gear and shaft.Standard clearance:
KOYO made bearing:0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made bearing:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:KOYO made:
0.058 mm (0.0023 in.)NSK made:
0.056 mm (0.0022 in.)If the clearance exceeds the maximum, replace the1st gear or 1st gear needle roller bearing.
4. INSPECT 2ND GEAR RADIAL CLEARANCE(a) Using a dial gauge, measure the 2nd gear radial
clearance between the gear and shaft.Standard clearance:
KOYO made:0.015 to 0.058 mm (0.0006 to 0.0023 in.)
NSK made:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:KOYO made:
0.058 mm (0.0023 in.)NSK made:
0.056 mm (0.0022 in.)If the clearance exceeds the maximum, replace the2nd gear or 2nd gear needle roller bearing.
C080538
C068312
C068309
C068254
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C50 MANUAL TRANSAXLE – OUTPUT SHAFT MX–87
5. REMOVE 4TH DRIVEN GEAR(a) Using SST and a press, remove the output shaft
rear bearing and 4th driven gear from the outputshaft.SST 09950-00020
6. REMOVE OUTPUT GEAR SPACER(a) Remove the output gear spacer from the output
shaft.
7. REMOVE 2ND GEAR(a) Using SST and a press, remove the 3rd driven gear
with 2nd gear from the output shaft.SST 09950-00020
8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING(a) Remove the 2nd gear needle roller bearing and 2nd
gear bearing spacer from the output shaft.
9. REMOVE SYNCHRONIZER RING NO.1 (FOR 2NDGEAR)(a) Remove synchronizer ring No. 1 from the output
shaft.
SST
C080539E02
C068005
SST
G027264E02
C080541
C120730
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MX–88 C50 MANUAL TRANSAXLE – OUTPUT SHAFT
MX
10. REMOVE 1ST GEAR(a) Using 2 screwdrivers and a hammer, remove the
clutch hub No. 1 shaft snap ring from the outputshaft.HINT:Use a shop rag or piece of cloth to keep the shaftsnap ring from flying off.
(b) Using SST and a press, remove the clutch hub No.1 assembly and 1st gear from the output shaft.SST 09950-00020NOTICE:• Do not tighten SST excessively.• Support the input shaft by hand to prevent it
from dropping off.
11. REMOVE SYNCHRONIZER RING GEAR NO.1 (FOR1ST GEAR)(a) Remove synchronizer ring No. 1 from the 1st gear.
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING(a) Remove the 1st gear needle roller bearing from the
output shaft.
13. REMOVE 1ST GEAR THRUST WASHER(a) Remove the 1st gear thrust washer from the output
shaft.
C080543
SST
C080544E02
C080465
C068012
C068013
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C50 MANUAL TRANSAXLE – OUTPUT SHAFT MX–89
14. REMOVE 1ST GEAR THRUST WASHER PIN ORBALL(a) Remove the 1st gear thrust washer pin or ball from
the output shaft.
15. REMOVE REVERSE GEAR(a) Remove the reverse gear, 3 synchromesh shifting
keys and 3 synchromesh shifting key springs fromtransmission clutch hub No. 1.NOTICE:Use a shop rag or piece of cloth to keep theshifting key and shifting key spring from flyingoff.
INSPECTION1. INSPECT OUTPUT SHAFT
(a) Using a dial gauge and 2 V-blocks, check the outputshaft runout.Maximum runout:
0.015 mm (0.0006 in.)If the runout exceeds the maximum, replace theoutput shaft.
(b) Using a micrometer, measure the outer diameter ofthe output shaft journal surface, at the locationsindicated.Standard outer diameter:
Part A:31.985 to 32.000 mm (1.2592 to 1.2598 in.)
Part B:37.985 to 38.000 mm (1.4955 to 1.4961 in.)
Part C:32.985 to 33.000 mm (1.2986 to 1.2992 in.)
If the outer diameters are less than the minimums,replace the output shaft.
C068014
C068015
C080545
A B C
C080439E01
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C50 MANUAL TRANSAXLE – OUTPUT SHAFT MX–91
6. INSPECT SYNCHRONIZER RING NO.1 (FOR 1STGEAR)(a) Check for wear and damage.(b) Coat the 1st gear cone with gear oil.(c) Turn the synchronizer ring in one direction while
pushing it against the 1st gear cone.(d) Check that the ring locks.
If the synchronizer ring does not lock, replace thesynchronizer ring.
(e) Using a feeler gauge, measure the clearancebetween the synchronizer ring back and the gearspline end.Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)Minimum clearance:
0.75 mm (0.0295 in.)If the clearance is less than the minimum, replace
the synchronizer ring.
7. INSPECT REVERSE GEAR(a) Using a vernier calipers, measure the width of the
reverse gear groove (A) and the thickness of theclaw part on the reverse shift fork (B), and calculatethe clearance.Standard clearance (A - B):
0.15 to 0.35 mm (0.0059 to 0.0138 in.)If the clearance is outside the specifications, replacethe reverse gear and reverse shift fork.
8. INSPECT TRANSMISSION CLUTCH HUB NO.1(a) Check that transmission clutch hub No. 1 and the
reverse gear slide smoothly.(b) Check that the edges of the reverse gear spline
gear are not worn down.
C080457
C080458
Clearance = (A - B)
B
A
C068409E01
C068240
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MX–92 C50 MANUAL TRANSAXLE – OUTPUT SHAFT
MX
REASSEMBLY1. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil and install it ontotransmission clutch hob No. 1.NOTICE:Orient the reverse gear and transmission clutchhub No. 1 correctly.
(b) Install the 3 synchromesh shifting key springs and 3synchromesh keys onto transmission clutch hub No.1.
2. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL(a) Coat the 1st gear thrust washer pin or ball with MP
grease, and install it onto the output shaft.
3. INSTALL 1ST GEAR THRUST WASHER(a) Coat the 1st gear thrust washer with gear oil and
install it onto the output shaft.
4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING(a) Coat the 1st gear needle roller bearing with gear oil
and install it onto the output shaft.
5. INSTALL 1ST GEAR(a) Coat the 1st gear with gear oil and install it onto the
output shaft.
C068241
C068014
C068013
C068012
C068310
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C50 MANUAL TRANSAXLE – OUTPUT SHAFT MX–93
6. INSTALL SYNCHRONIZER RING NO.1 (FOR 1STGEAR)(a) Coat synchronizer ring No. 1 with gear oil and install
it onto the 1st gear.
7. INSTALL TRANSMISSION CLUTCH HUB NO.1(a) Using SST and a press, install transmission clutch
hub No. 1 onto the output shaft.SST 09316-60011 (09316-00031)HINT:• The 1st gear can be turned.• While checking that the 1st gear thrust washer
pin or ball is inserted into the groove of the 1st
gear thrust washer, press and fit the clutch hubNo. 1.
(b) Select a snap ring that will allow minimum axial play.Standard clearance:
0.1 mm (0.039 in.) or lessSnap ring thickness
(c) Using a brass bar and a hammer, install the snapring onto the output shaft.NOTICE:Do not damage the journal surface of the outputshaft.
8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING(a) Coat the 2nd gear needle roller bearing and 2nd
gear bearing spacer with gear oil, and install themonto the output shaft.
C080470
SST
C080547E01
C068244
MarkThickness mm
(in.)Mark
Thickness mm
(in.)
A 2.50 (0.0984) D 2.68 (0.1055)
B 2.56 (0.1008) E 2.74 (0.1079)
C 2.62 (0.1031) F 2.80 (0.1102)
C068246
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MX–94 C50 MANUAL TRANSAXLE – OUTPUT SHAFT
MX
9. INSTALL SYNCHRONIZER RING NO.1 (FOR 2NDGEAR)(a) Coat synchronizer ring No. 1 with gear oil and install
it onto the 2nd gear.
10. INSTALL 2ND GEAR(a) Coat the 2nd gear with gear oil and install it onto the
output shaft.
11. INSTALL 3RD DRIVEN GEAR(a) Using SST and a press, install the 3rd driven gear
onto the output shaft.SST 09316-60011 (09316-00031)
12. INSTALL OUTPUT GEAR SPACER(a) Install the output gear spacer onto the output shaft.
13. INSTALL 4TH DRIVEN GEAR(a) Using SST and a press, install the 4th driven gear
onto the output shaft.SST 09612-22011
C080471
C068248
SST
C080548E01
C068005
SST
C082013E01
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C50 MANUAL TRANSAXLE – OUTPUT SHAFT MX–95
14. INSTALL OUTPUT SHAFT REAR BEARING(a) Using SST and a press, install the output shaft rear
bearing onto the output shaft.SST 09612-22011
15. INSPECT 2ND GEAR RADIAL CLEARANCE(a) Using a dial gauge, measure the 2nd gear radial
clearance between the gear and shaft.Standard clearance:
KOYO made:0.015 to 0.058 mm (0.0006 to 0.00023 in.)
NSK made:0.015 to 0.056 mm (0.0006 to 0.0022 in.)
Maximum clearance:KOYO made:0.058 mm (0.0023 in.)
NSK made:0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the2nd gear or 2nd gear needle roller bearing.
16. INSPECT 1ST GEAR RADIAL CLEARANCE(a) Using a dial gauge, measure the 1st gear radial
clearance between the gear and shaft.Standard clearance:
KOYO made:
0.015 to 0.058 mm (0.0006 to 0.00023 in.)NSK made:
0.015 to 0.056 mm (0.0006 to 0.0022 in.)Maximum clearance:
KOYO made:0.058 mm (0.0023 in.)
NSK made:0.056 mm (0.0022 in.)
If the clearance exceeds the maximum, replace the1st gear or 1st gear needle roller bearing.
17. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial gauge, measure the 2nd gear thrustclearance.Standard clearance:
0.10 to 0.55 mm (0.0039 to 0.0217 in.)Maximum clearance:
0.55 mm (0.0217 in.)If the clearance exceeds the maximum, replacetransmission clutch hub No. 1, the 2nd gear or 3rddriven gear.
SST
C082014E01
C068254
C068309
C068312
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MX–96 C50 MANUAL TRANSAXLE – OUTPUT SHAFT
MX
18. INSPECT 1ST GEAR THRUST CLEARANCE(a) Using a feeler gauge, measure the 1st gear thrust
clearance.Standard clearance:
0.10 to 0.40 mm (0.0039 to 0.0157 in.)Maximum clearance:
0.40 mm (0.0157 in.)If the clearance exceeds the maximum, replace the1st gear thrust washer, 1st gear or transmissionclutch hub No. 1.C080538
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C50 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT MX–97
TRANSMISSIONC50MANUAL TRANSAXLE
SHIFT AND SELECT LEVER SHAFT
COMPONENTS
SELECT SPRING
NO.1 SEAT SHAFT
SNAP RING
SELECT SPRING SEAT NO.2
SHIFT LEVER INNER NO.1
SHIFT LEVER INNER NO.2
E-RING
COMPRESSION SPRING
SHIFT INTER LOCK PLATE
COMPRESSION SPRING
SELECT SPRING SEAT NO.1
SLOTTED SPRING PIN
SLOTTED SPRING PIN
SLOTTED SPRING PIN
SELECT INNER LEVER
SHIFT AND SELECT LEVER SHAFT
Non-reusable part Apply MP greaseC118357E01
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MX–98 C50 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT
MX
DISASSEMBLY1. REMOVE SELECT SPRING SEAT NO.2
(a) Using a screwdriver, remove the select spring No. 2seat E-ring, select spring seat No. 2 and selectreturn compression spring No. 2 from the shift andselect lever shaft.
2. REMOVE SHIFT LEVER INNER NO.2(a) Using a pin punch (φ5 mm) and a hammer, remove
the shift inner lever slotted spring pin and shift leverinner No. 2 from the shift and select lever shaft.HINT:Check the orientation of shift lever inner No. 2.
3. REMOVE SHIFT LEVER INNER NO.1(a) Using a pin punch (φ5 mm) and a hammer, remove
the shift inner lever slotted spring pin, shift leverinner No. 1 and shift inter lock plate from the shiftand select lever shaft.HINT:Check the orientation of shift lever inner No. 1.
4. REMOVE SELECT INNER LEVER(a) Using a pin punch (φ5 mm) and a hammer, remove
the select inner lever slotted spring pin, select innerlever, select return compression spring No. 1 andselect spring seat No. 1 from shift and select levershaft.HINT:Check the orientation of the select inner lever.
5. REMOVE SELECT SPRING NO.1 SEAT SHAFT SNAPRING(a) Using 2 screwdrivers and a hammer, remove the
select spring No. 1 seat shaft snap ring.
C120733
C120734
C121093
C120736
C120737
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C50 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT MX–99
REASSEMBLY1. INSTALL SELECT SPRING NO.1 SEAT SHAFT SNAP
RING(a) Coat the shift and select lever shaft with MP grease,
and install a snap ring onto the shift and select levershaft using a brass bar and a hammer.
2. INSTALL SELECT INNER LEVER(a) Coat select spring seat No. 1 with MP grease.(b) Using a pin punch (φ5 mm) and a hammer, install
select spring seat No. 1, select return compressionspring No. 1, the select inner lever and select innerlever slotted spring pin onto the shift and selectlever.Drive in depth:
3.0 to 4.0 mm (0.1181 to 0.1575 in)
3. INSTALL SHIFT LEVER INNER NO.1(a) Coat the shift inter lock plate and shift lever inner
No. 1 with MP grease.(b) Using a pin punch (φ5 mm) and a hammer, install
the shift inter lock plate, shift lever inner No. 1 andshift inner lever slotted spring pin onto the shift andselect lever shaft.Drive in depth:
-0.5 to 0.5 mm (-0.0197 to 0.0197 in.)
4. INSTALL SHIFT LEVER INNER NO.2(a) Coat shift lever inner No. 2 with MP grease.(b) Using a pin punch (φ5 mm) and a hammer, install
shift lever inner No. 2 and shift inner lever slottedspring pin onto the shift and select lever shaft.Drive in depth:
1.0 to 2.0 mm (0.0394 to 0.0787 in.)
5. INSTALL SELECT SPRING SEAT NO.2(a) Coat select spring seat No. 2 with MP grease.(b) Install select spring seat No. 2 and select return
compression spring No. 2. Using pliers, install a newselect spring seat No. 2 E-ring onto the shift andselect lever shaft.
C120738
C120753
C120754
C121091
C120739
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MX–100 C50 MANUAL TRANSAXLE – DIFFERENTIAL CASE
MX
TRANSMISSIONC50 MANUALTRANSAXLE
DIFFERENTIAL CASE
COMPONENTS
FRONT DIFFERENTIAL PINION SHAFT NO.1
FRONT DIFFERENTIAL RING GEAR
FRONT DIFFERENTIAL SIDE GEAR
FRONT DIFFERENTIAL CASE
FRONT DIFFERENTIAL PINION
FRONT DIFFERENTIAL PINION
FRONT DIFFERENTIAL
SIDE GEAR THRUST
WASHER NO.1
FRONT DIFFERENTIAL SIDE GEAR
FRONT DIFFERENTIAL
SIDE GEAR THRUST
WASHER NO.1
FRONT DIFFERENTIAL
PINION SHAFT
STRAIGHT PIN
x8
N*m (kgf*cm, ft*lbf) :Specified torque
77 (790, 57)SPEEDOMETER DRIVE GEAR
FRONT DIFFERENTIAL
PINION THRUST WASHER
FRONT DIFFERENTIALPINION THRUST WASHER
C118355E01
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C50 MANUAL TRANSAXLE – DIFFERENTIAL CASE MX–101
DISASSEMBLY1. REMOVE SPEEDOMETER DRIVE GEAR
(a) Remove the speedometer drive gear from the frontdifferential case.
2. REMOVE FRONT DIFFERENTIAL RING GEAR(a) Place matchmarks on the front differential ring gear
and the front differential case.(b) Remove the 8 bolts.
(c) Using a plastic hammer, remove the front differentialring gear from the front differential case.
3. INSPECT FRONT DIFFERENTIAL SIDE GEARBACKLASH(a) Fix the front differential pinion to the front differential
case side. Using a dial indicator, measure the frontdifferential side gear backlash.Standard backlash:
0.05 to 0.20 mm (0.0020 to 0.0079 in.)If the backlash is outside the specifications, replacethe side gear thrust washers.
4. REMOVE FRONT DIFFERENTIAL PINION SHAFTSTRAIGHT PIN(a) Using a chisel and a hammer, loosen the staked
part of the front differential case.
C067982
Matchmarks
D032380E01
C067984
C067989
C067985
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MX–102 C50 MANUAL TRANSAXLE – DIFFERENTIAL CASE
MX
(b) Using a pin punch (φ3 mm) and a hammer, removethe front differential pinion shaft straight pin from thefront differential case.
5. REMOVE FRONT DIFFERENTIAL PINION SHAFTNO.1(a) Remove front differential pinion shaft No. 1 from the
front differential case.
6. REMOVE FRONT DIFFERENTIAL SIDE GEAR(a) Remove the 2 front differential pinions, 2 front
differential pinion thrust washers, 2 front differentialside gear thrust washers No. 1 and 2 frontdifferential side gears from the front differentialcase.HINT:Revolving the front differential pinion, remove the 2pinions and 2 side gears.
INSPECTION1. INSPECT FRONT DIFFERENTIAL PINION THRUST
WASHER(a) Using a micrometer, measure the thickness of the
front differential pinion thrust washer.Minimum thickness:
0.94 mm (0.03701 in.)If the thickness is less than the minimum, replacethe front differential pinion thrust washer.
2. INSPECT FRONT DIFFERENTIAL PINION SHAFTNO.1(a) Using a micrometer, measure the outer diameter of
front differential pinion shaft No. 1.Minimum outer diameter:
16.982 mm (0.6685 in.)If the outer diameter is less than the minimum,replace front differential pinion shaft No. 1.
C067986
C067987
C067988
C068517
C068518
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C50 MANUAL TRANSAXLE – DIFFERENTIAL CASE MX–103
REASSEMBLY1. INSTALL FRONT DIFFERENTIAL SIDE GEAR
(a) Coat the sliding and rotating surfaces of the frontdifferential side gear with gear oil.
(b) Install the 2 front differential side gear thrustwashers No. 1 onto the 2 front differential sidegears.
(c) Install the 2 front differential side gears, 2 frontdifferential pinions and 2 front differential pinionthrust washers onto the front differential case.HINT:Revolving the front differential side gear, install the 2front differential pinions and 2 front differentialpinion thrust washers.
2. INSTALL FRONT DIFFERENTIAL PINION SHAFTNO.1(a) Coat front differential pinion shaft No. 1 with MP
grease.
(b) Install front differential pinion shaft No. 1 onto thefront differential case so that the hole for the frontdifferential pinion shaft straight pin is aligned withthe hole in the front differential case.
3. ADJUST FRONT DIFFERENTIAL SIDE GEARBACKLASH(a) Fix the front differential pinion to the front differential
case side. Using a dial indicator, measure the frontdifferential side gear backlash.
Standard backlash:0.05 to 0.20 mm (0.0020 to 0.0079 in.)
If the backlash is outside the specifications, replacethe side gear thrust washer.Thrust washer thickness
HINT:• Because the thrust washer does not have any
marks for distinction, measure the thickness witha micrometer to select a proper thrust washer.
• Select washers of the same thickness for boththe right and left.
C067988
C067987
C067989
Parts No. Thickness mm (in.)
41361 - 22140 0.95 (0.0374 in.)
41361 - 22020 1.00 (0.0394 in.)
41361 - 22150 1.05 (0.0413 in.)
41361 - 22030 1.10 (0.0433 in.)
41361 - 22160 1.15 (0.0452 in.)
41361 - 22040 1.20 (0.0472 in.)
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MX–104 C50 MANUAL TRANSAXLE – DIFFERENTIAL CASE
MX
4. INSTALL FRONT DIFFERENTIAL PINION SHAFTSTRAIGHT PIN(a) Using a pin punch (φ3 mm) and a hammer, install
the front differential pinion shaft straight pin onto thefront differential case.
(b) Using a chisel and a hammer, stake the frontdifferential case hole.
5. INSTALL FRONT DIFFERENTIAL RING GEAR(a) Clean the contact surfaces of the front differential
case and ring gear.(b) Using a heater, heat the front differential ring gear to
90 to 110°C (194.0 to 230.0°F).(c) After the moisture on the ring gear has completely
evaporated, quickly install the ring gear onto thedifferential case.
(d) Aligning the 2 matchmarks, quickly install the frontdifferential ring gear onto the front differential case.
(e) Install the 8 bolts.Torque: 77 N*m (790 kgf*cm, 57 ft.*lbf)
C067990
C067991
90 to 110
C058905E07
